contract documents volume iv of vi...

Bids will be opened at 1:30 pm, Wednesday, October 16, 2013 in the Board Room, Second Floor of the District’s Administration Building, 375 11th Street, Oakland, California

CONTRACT DOCUMENTS

VOLUME IV OF VI

SPECIFICATIONS AND APPENDICES(DIVISIONS 40-44, APPENDICES)

SPECIFICATION 2047

SET NO. ________________

EL PORTAL RESERVOIR REHABILITATION ANDALMOND PUMPING PLANT REPLACEMENT

EAST BAY MUNICIPAL UTILITY DISTRICT

SPECIFICATION 2047


TABLE OF CONTENTS

VOLUME I - BIDDING DOCUMENTS AND SPECIFICATIONS (DIVISIONS 00 THROUGH 04)

DIVISION 00 - PROCUREMENT AND CONTRACTING DOCUMENTS00 01 10 Table of Contents

00 11 13 Notice to Contractors

00 21 13 Instructions to Bidders

00 30 05 Offices to Contact

00 31 22 Dive Report Information

00 31 24 Materials Assessment Information

00 31 32 Geotechnical Data

00 41 02 Bid Form

00 41 05 Description of Bid Items

00 42 00 Proposal

00 43 13 Bidder’s Bond

00 43 39 Contract Equity Program and Equal Employment Opportunity Guidelines

00 45 13 Bidder's Qualifications and References

00 45 14 Manufacturer Form

00 45 19 Declaration of Noncollusion

00 45 46 Declaration of Eligibility to Work on Public Works Projects

00 51 00 Execution of Contract

00 52 00 Contract

00 61 13.13 Faithful Performance Bond

00 61 13.16 Payment Bond

00 62 00 Insurance Requirements

00 62 16.11 Certificate of Workers' Compensation Insurance

00 62 16.13 Certificate of Commercial General and Auto Liability Insurance

08/19/132047 00 01 10 - 1 Table of Contents

00 62 16.14 Certificate of Pollution Liability Insurance

00 62 16.15 Certificate of Builder's Risk Insurance

00 72 00 General Conditions

00 73 00 Supplementary General Conditions

DIVISION 01 - GENERAL REQUIREMENTS01 11 00 Summary of Work

01 14 00 Work Restrictions

01 21 00 Allowances

01 24 13 Value Engineering

01 29 00 Payment Procedures

01 31 19 Project Meetings

01 31 23.10 Web-based Construction Document Management

01 32 00 Construction Progress Documentation

01 33 00 Submittal Procedures

01 35 24 Project Safety Requirements

01 35 44 Environmental Requirements

01 35 53 Security Procedures

01 42 19 Reference Standards

01 43 11 Seismic Requirements

01 45 27 Shop Inspection

01 50 00 Temporary Facilities and Controls

01 55 26 Traffic Regulation

01 61 00 Common Product Requirements

01 61 01 Electrical Requirements for Mechanical Package Systems

01 64 05 District-Furnished Materials

01 74 05 Cleaning

01 75 17 Field Testing and Startup

01 77 00 Closeout Procedures

01 79 00 Demonstration and Training

01 91 13.10 Asset Identification Tags


DIVISION 02 – EXISTING CONDITIONS02 21 13 Construction Survey

02 41 13 Selective Site Demolition

02 82 13 Asbestos Abatement

02 83 13 Lead Hazard Control Activities

DIVISION 03 - CONCRETE03 11 00 Concrete Forming

03 15 13 Waterstops

03 20 00 Concrete Reinforcing

03 30 00 Cast-in-Place Concrete

03 35 00 Concrete Finishing

03 35 20 Concrete Architectural Finishes

03 39 00 Concrete Curing

03 41 00 Precast Structural Concrete

03 48 00 Precast Concrete Specialties

03 62 00 Non-Shrink Grouting

03 62 19 Repair Mortar

DIVISION 04 – MASONRY04 23 00 Glass Unit Masonry

VOLUME II - SPECIFICATIONS (DIVISIONS 05 THROUGH 26)

DIVISION 05 - METALS05 05 14 Hot-Dip Galvanizing

05 05 24 Pipe Welding

05 05 26 Flange Bolting

05 12 00 Structural Steel Framing

05 31 00 Steel Decking

05 40 00 Cold-Formed Metal Framing

05 50 00 Metal Fabrications


DIVISION 06 - WOOD, PLASTICS, AND COMPOSITES06 10 53 Miscellaneous Rough Carpentry

DIVISION 07 - THERMAL AND MOISTURE PROTECTION07 12 00 Bituminous Waterproofing

07 19 00 Water Repellents

07 21 00 Thermal Insulation

07 22 00 Roof and Deck Insulation

07 33 13 Asphalt Shingles

07 60 00 Flashing and Sheet Metal

07 72 25 Reservoir Roof Vent

07 92 00 Joint Sealants

DIVISION 08 - OPENINGS08 31 05 Access Hatches and Vault Hatches

08 31 10 Roof Hatches

08 33 23 Overhead Coiling Doors

08 34 73 Sound Control Door Assemblies

08 71 00 Door Hardware

08 91 00 Louvers

DIVISION 09 - FINISHES09 22 10 Non-Structural Metal Framing

09 29 00 Gypsum Board

09 84 10 Acoustical Panels

09 91 00 Painting

09 96 35.05 Zinc-Rich Coatings

09 96 56.05 High-Build Epoxy Coatings

09 96 56.10 Fusion-Bonded Epoxy Coatings

09 96 57 Mechanical and Electrical Coating Systems

09 97 23 Coating Systems for Concrete Structures


DIVISION 10 – SPECIALITIES10 14 00 Signage

10 28 00 Toilet Accessories

10 44 00 Fire Protection Specialties

DIVISION 11 – NOT USED

DIVISION 12 - FURNISHINGS12 31 01 Shop Furniture

DIVISIONS 13 THROUGH 21 – NOT USED

DIVISION 22 - PLUMBING22 13 16 Sanitary Waste and Vent Piping

22 30 00.01 Plumbing Fixtures and Equipment

22 45 00 Emergency Plumbing Fixtures

DIVISION 23 - HEATING, VENTILATING, AND AIR CONDITIONING23 05 03 Testing, Adjusting and Balancing HVAC

23 07 00 HVAC Insulation

23 09 13.13 Actuators and Operators for HVAC

23 31 13 Metal Ducts

23 33 00 Air Duct Accessories

23 34 00 HVAC Fans

23 73 13.10 Precision Air Handler Units


DIVISION 26 - ELECTRICAL26 05 00 Common Work Results for Electrical

26 05 13 Medium-Voltage Cables

26 05 19 Low-Voltage Electrical Power Conductors and Cables


26 05 26 Grounding and Bonding for Electrical Systems

26 05 33 Raceway and Boxes for Electrical Systems

26 05 36 Cable Trays for Electrical Systems

26 05 43 Underground Ducts and Raceways for Electrical Systems

26 05 53 Identification for Electrical Systems

26 05 83 Low Voltage Motors

26 08 00 Commissioning of Electrical Systems

26 09 13 Electrical Power Monitoring and Control

26 09 23 Lighting Control Devices

26 13 23 Medium-Voltage Metalclad Switchgear

26 18 40 Medium-Voltage Variable Frequency Drives26 22 13 Low-Voltage Distribution Transformers

26 24 16 Panelboards

26 27 26 Wiring Devices

26 28 13 Fuses

26 28 16 Enclosed Switches and Circuit Breakers

26 29 13.13 Across the Line Motor Controllers

26 51 13 Interior Lighting Fixtures, Lamps, and Ballasts

26 52 00 Emergency Lighting

26 53 00 Exit Signs

VOLUME III - SPECIFICATIONS (DIVISIONS 27 THROUGH 39)

DIVISION 27 - COMMUNICATIONS27 05 00 Common Work Results for Communications

27 08 00 Commissioning of Communications Systems

27 11 13 Communications Entrance Protection

27 11 19 Communications Terminal Blocks and Patch Panels

27 13 23 Communications Optical Fiber Backbone Cabling

27 15 00.16 Voice Communications Horizontal Cabling

27 15 43 Communications Faceplates and Connectors

27 21 16 Data Communications Routers, CSU/DSU, Multiplexers, Codecs, and Modems

27 21 23 Data Communications Switches and Hubs


DIVISION 28 – ELECTRONIC SAFETY AND SECURITY28 13 33.16 Access Control Interfaces to Access Door Control

28 16 19 Intrusion Detection Remote Devices and Sensors


DIVISION 31 - EARTHWORK31 11 00 Clearing and Grubbing

31 23 16 Excavation

31 23 19 Dewatering

31 23 23 Fill

31 23 23.15 Imported Backfill and Drain Rock Materials

31 23 23.33 Controlled Density Fill

31 23 23.34 Controlled Low Strength Material

31 34 19.13 Geosynthetic Filter Fabric

31 63 29 Drilled Shafts and Soldier Piles

DIVISION 32 - EXTERIOR IMPROVEMENTS 32 12 16 Asphalt Paving

32 12 16.81 Asphalt Pavement Replacement

32 31 13 Chain Link Fence and Gates

32 32 23.1632 84 00

Concrete Modular Retaining WallPlanting Irrigation

32 90 00 Planting

DIVISION 33 - UTILITIES33 09 11 Instruments and Recorders

33 09 70 Instrumentation and Control for Electrical Utilities

33 10 01 Protection from Corrosion

33 11 03 Fabrication of Steel Pipe – 24-inch and Larger

33 11 06 Fabricated Pipe Specials


33 11 07 Specialty Couplings for Mechanical Piping

33 11 13.05 Installation of Steel Pipe

33 11 13.10 Polywrap

33 11 13.35 Fabrication and Installation of High Density Polyethylene Pipe

33 11 13.50 Mortar Lining for Steel Pipe

33 11 13.60 Mortar Coating for Steel Pipe

33 11 13.62 Dielectric Coatings for Steel Pipe

33 12 01 Basic Mechanical Materials and Methods

33 12 16.05 Miscellaneous Valves

33 12 16.11 Resilient-Seated Gate Valves

33 12 16.15 AWWA Butterfly Valves

33 12 16.16 High Performance Butterfly Valves

33 12 16.20 Dual-Disc Check Valves

33 12 16.27 AWWA Ball Valves

33 12 16.32 Powered Valve Actuators

33 12 16.40 Surge Control-Pressure Relief Valve

33 12 23.10 Vertical Turbine Pumps

33 12 23.12 Vertical Turbine Pump Motors

33 12 27.11 Strainers and Filters

33 12 28.11 Miscellaneous Piping Specialties

33 16 02 Reservoir Draining and Sediment Removal

33 16 05 Concrete Reservoir Leakage Testing

33 46 16 Subdrainage Piping

33 46 23.19 Geosynthetic Drainage Layers

33 46 26 Geotextile Subsurface Drainage Filtration

33 71 19 Electrical Underground Ducts and Manholes

33 72 33 Control House Equipment



VOLUME IV - SPECIFICATIONS (DIVISIONS 40 THROUGH 44, and APPENDICES)

DIVISION 40 - PROCESS INTEGRATION40 01 70 Supplemental Training Requirements for Process Integration

40 20 20 Mechanical Piping

40 42 13.10 Process Piping Thermal Insulation

40 80 00 Commissioning of Process Systems

40 90 00 Instrumentation and Control for Process Systems

40 94 13 Digital Process Control Computers

40 94 33 Operator Interface Units

40 94 43 Programmable Logic Process Controllers

40 95 13 Process Control Panels and Hardware

DIVISION 41 - MATERIAL PROCESSING AND HANDLING EQUIPMENT41 22 13.13 Overhead Bridge Cranes


DIVISION 43 - PROCESS GAS AND LIQUID HANDLING, PURIFICATION ANDSTORAGE EQUIPMENT

43 21 13.15 In-Line Centrifugal Pumps


APPENDIX A – Forms and Schedules

APPENDIX B – Materials Assessment Testing

APPENDIX C – Listing of Sole Source Products

APPENDIX D – Alameda County Encroachment Permit Forms and Traffic Control Plan

APPENDIX E – Title 22 Regulated VOCs

VOLUMES V AND VI – DRAWINGS (bound separately)

Volume V - El Portal Reservoir RehabilitationVolume VI - Almond Pumping Plant Replacement


SECTION 40 01 70

SUPPLEMENTAL TRAINING REQUIREMENTS FOR PROCESS INTEGRATION PART 1 - GENERAL

1.1 DESCRIPTION

A. Work included: Perform training of District personnel for furnished or installed Process Control equipment, systems, software, and networks. Develop trainingprogram including scheduling, and coordination of training activities and training materials. Training procedures and requirements found in Specification Section 01 79 00 shall also apply.

B. Related sections:

1. Section 01 79 00 - Demonstration and Training

C. Tailor the training program to meet the specific needs of District personnel. Include classroom and field instruction for engineers, operators and maintenance personnel.

D. A "week" shall consist of 40 hours of actual instruction time. A "day" shall consist of 8 hours of actual instruction time. The actual training schedule shall be coordinated with the District.

1.2 OWNER’S INSTRUCTIONS

A. Operations and Maintenance Training: O&M training for each primary element and subsystem shall be in accordance with the requirements specified under the associated section. All training shall be given using equipment similar to the equipment provided in these Contract Documents.

B. The bid shall include the following number of days of training time and round tripsfor Operations and Maintenance training services described in this Section for a representative from the Process Control Systems Contractor (PCSC):

08/19/13 Supplemental Training Requirements2047 40 01 70 - 1 For Process Integration

Site Days/Hours Number of Round Trips

Almond Pumping PlantO&M Training –

Session # 1

1 day

@

8 hours per day

1

Almond Pumping PlantO&M Training –

Session # 2

1 day

@

8 hours per day

1

1. The content of training shall include the following:

a. Loop Functions: Understanding the details of each loop and how they function.

b. Calibration and adjustment.

c. Adjustments: For example, controller tuning constants, current switch trip points, etc.

d. Troubleshooting and diagnosis.

e. Component removal and replacement: For example, whole units.

f. Periodic maintenance.

2. The representative from the PCSC shall be present at the site or classroom designated in Section 01 79 00, for the minimum person-days listed, travel time excluded. This training shall be provided for each type of component and function provided in and by the Process Control System (PCS), excluding programming of the PCS.

3. Each training session will have 16 attendees.

4. Schedule this training so that it does not overlap with any of the other training specified in this Section.

5. The content of both of the training sessions shall be identical. The bid shall not assume that the two training sessions will overlap or will occur in one round trip by the manufacturer’s representative. Two separate maintenance workgroups will attend the training and the sessions will be scheduled at a


mutually convenient time for all parties. The bid should plan for two independent mobilizations and round trips on the part of the PCSC representative.

C. Process Control System (PCS) PLC Training:

1. The bid shall include the following number of days of training time and round trips for training services described in this Section for a certified Rockwell Personal Trainer:


Almond Pumping Plant PCS PLC Training –

Session # 1

4 consecutive days

@

8 hours per day

1

Almond Pumping PlantPCS PLC Training –

Session # 2

4 consecutive days

@

8 hours per day

1

2. The Contractor shall provide the following tailored, on-site training conducted by a certified Rockwell Personal Trainer at the training location specified in Section 01 79 00:

a. A training session similar in format and content to Rockwell course number CCPS41, with the exception that the course should completelyconcentrate on the MicroLogix 1400 hardware specified on this project.General course content shall be as follows:

a. Identifying all MicroLogix 1400 hardware components used in the project.

b. Communicating with a MicroLogix 1400 processor using RSLogix 500 software.

c. Ethernet DNP 3.0 and Modbus RTU communications.

d. Creating a new project.

e. Determining addresses; assigning symbols; entering, editing, and verifying ladder logic; organizing the data table.


f. Determining program flow and creating subroutines.

g. Entering and searching for documentation.

h. Testing a project.

b. The training course shall be hands-on, with the instructor providing training workstations for each attendee having hardware identical to that specified on this project. In this course, attendees shall create a sample program, step-by-step, to meet the requirements of a given functional specification using RSLogix 500. Each lesson in the course shall be devoted to a step in the programming sequence, with the instructor presenting each step and demonstrating the procedure required to complete it using the training workstations.

c. At the conclusion of the course, attendees should be able to use RSLogix 500 to select the appropriate instructions, draft, program, and test ladder logic with the MicroLogix 1400 hardware. Attendees should also be able to set up Ethernet DNP 3.0 and Modbus RTU communication.

3. Each training session will have 16 attendees.


5. The content of both of the training sessions shall be identical. The bid shall not assume that the two training sessions will overlap or will occur in one round trip by the manufacturer’s representative. Two separate maintenance workgroups will attend the training and the sessions will be scheduled at a mutually convenient time for all parties. The bid should plan for two independent mobilizations and round trips on the part of the Rockwell Personal Trainer.

D. SCADA RTU Training:

1. The bid shall include the following number of days of training time and round trips for training services described in this Section for a certified Schneider Electric Control Microsystems Personal Trainer:



Almond Pumping Plant SCADA RTU Training

– Session # 1

4 consecutive days

@

8 hours per day

1

Almond Pumping Plant SCADA RTU Training

– Session # 2

4 consecutive days

@

8 hours per day

1

2. The Contractor shall provide the following tailored, on-site training conducted by a certified Schneider Electric Control Microsystems Personal Trainer at the training location specified in Section 01 79 00:

a. “Telepace Studio Programming and SCADAPack Controller Three Day Training Session”. General course content shall be as follows:

a. SCADAPack controller hardware.

b. Series 5000 I/O modules.

c. Telepace ladder logic software

d. SCADAPack controller communication.

b. “DNP3 Protocol Configuration One Day Training Session”. General course content shall be as follows:

a. DNP3 protocol configuration, including master mode, slave mode, unsolicited messages, object classes, and Ethernet and serial communication.

3. Telepace Studio and DNP3 training sessions shall be completed back-to-back in an overall four day training program with 16 attendees.


5. The content of both of the training sessions shall be identical. The bid shall not assume that the two training sessions will overlap or will occur in one round trip by the manufacturer’s representative. Two separate maintenance


workgroups will attend the training and the sessions will be scheduled at a mutually convenient time for all parties. The bid should plan for two independent mobilizations and round trips on the part of the Schneider Electric Control Microsystems Personal Trainer.

1.3 SUBMITTALS

A. Submittals shall be made in accordance with Section 01 33 00 Submittal Procedures.

PART 2 - NOT USED

PART 3 - NOT USED

END OF SECTION


SECTION 40 20 20

MECHANICAL PIPING

PART 1 - GENERAL

1.1 DESCRIPTION

A. Work included: Furnish and install all piping and piping appurtenances as shown on the drawings and as specified herein.

B. Work not included: factory production of pipe and fabricated fittings 24-inch and larger and installation, as shown on Drawings W-10030-1 through -24, which is covered by the following Sections:

1. Section 33 11 03 – Fabrication of Steel Pipe - 24-inch and Larger

2. Section 33 11 13.05 – Installation of Steel Pipe

C. Related work specified elsewhere:

1. Section 01 75 17 – Field Testing and Startup.

2. Section 01 45 27 – Shop Inspection

3. Section 05 05 24 – Pipe Welding.

4. Section 05 05 26 – Flange Bolting.

5. Section 05 50 00 – Metal Fabrications.

6. Section 09 96 56.05 – High-Build Epoxy Coatings

7. Section 09 96 56.10 – Fusion Bonded Epoxy Coatings.

8. Section 22 05 53.05 – Pipe Identification.

9. Section 22 13 16 – Sanitary Waste and Vent Piping.

10. Section 26 05 00 – Common Work Results for Electrical.

11. Section 31 23 16 – Excavation.

12. Section 33 10 01 – Protection from Corrosion.

13. Section 33 11 06 – Fabricated Pipe Specials.

14. Section 33 11 07 – Specialty Couplings for Mechanical Piping.

08/19/132047 40 20 20 - 1 Mechanical Piping

15. Section 33 11 13.05 – Installation of Steel Pipe.

16. Section 33 12 01 – Basic Mechanical Materials and Methods.

17. Section 33 12 27.11 – Strainers and Filters.

18. Section 33 12 28.11 – Miscellaneous Piping Specialties.

1.2 DELIVERY, STORAGE, AND HANDLING

A. Delivery: All materials that will not be installed the same day as delivered to the site shall be stored in the original manufacturer's packaging. Loose items with no original packaging shall be boxed to protect the products from scratches, abrasion, or breakage.

B. Protection Prior to Installation:

1. All products shall be transported, handled and stored in accordance with the manufacturer's recommendations.

2. All products shall be protected from excessive heat, moisture, and other adverse environmental conditions during storage and handling.

3. All plastic materials shall be stored out of direct sunlight.

1.3 SUBMITTALS

A. Submit Prior to Shipment:

1. Submit a list of pipe, fittings, and appurtenances to be used for the work. The list shall include the following information, where applicable:

a. Materials (show conformance with listed ASTM specifications).

b. Size/Schedule (show conformance with listed ASTM and ANSI specifications).

c. Pressure/Temperature Ratings.

d. Manufacturer.

2. A signed “Manufacturer’s Certificate of Compliance” stating that all material has been manufactured, passivated, sampled, tested and inspected in accordance with the specified standards. The applicable standards shall be listed on the certificate.

3. For steel and stainless steel pipe, flanges and fittings, chemical analysis certification report (mill test report and/or post-mill test report).


4. Manufacturers' published catalog information for all equipment and products.

5. Shop Fabrication Drawings:

a. Shop drawings for piping fabrication shall include the following details at a minimum:

1) Drawings shall contain scale plan, section and detail views.Sufficient detail shall be provided to fabricate and install the design.

2) Drawings shall contain complete piping dimensions for the fabrication of all piping sections.

3) Piping components shall be called out with sequentially numbered item bubbles.

4) All piping and fittings that are over 2” nominal size shall be drawn to scale in a two-line format. Piping that is 2” and smaller may be shown with a single line representation.

5) Drawings Material Lists: The “ITEM” column shall match the individual bubble call-outs. The “REQUIRED” column shall indicate exact quantities of components. Provide lengths rounded up.The “DESCRIPTION” column has the following required format: “Component, Size, Material with applicable material standard, Ratings with applicable construction standard, Configuration(s), End Type”. Refer to the example below.

EXAMPLE MATERIAL LIST

ITEM REQD DESCRIPTION

1 20 FT PIPE, 12”, STL ASTM A53 GR B, ASME B36.10 STD WT

2 6 FLANGE, 8”, STL ASTM A105, ASME B16.5 150 LB, SLIP-ON, FF

3 4 ELBOW, 6”, STL ASTM A105, ASME B16.9 STD WT, 45 DEG, BWE

4 2 THREADED OUTLET, 1” NPT OUTLET X 12” RUN, STL, 3000 LB

6. At the request of the Engineer, submit records of mathematical analyses or successful proof testing of the manufacturer’s wrought fitting design per ASME B16.9-2.2.

7. Factory, Shop and Field Finishes.

8. NSF/ANSI 61 certification for all materials in contact with drinking water.


9. Manufacturer's instructions for installation of products and equipment.

10. Pipe identification system.

B. Submit 45 Calendar Days Prior to Cleaning and Testing:

1. Cleaning and disinfection plan.

2. Piping Field Test Schedule: Each test shall be numbered and the boundaries shall be illustrated on the related P&ID. Refer to the “Mechanical Piping Schedule”.

3. Piping field test equipment and instrument calibration sheets.

C. Provide evidence of certification from the PVC and CPVC manufacturer(s) for personnel installing such materials, when requested by the Engineer.

D. Submit Prior to System Start-up:

1. All signed results and records of piping field testing, including “Piping Pressure Test Records”, to demonstrate that completion of all testing was successfully executed.

1.4 REFERENCES

A. American Water Works Association (AWWA):

1. C110, Ductile Iron and Gray-Iron Fittings, 3” through 48”.

2. C206, Field Welding of Steel Water Pipe.

3. C653, Disinfection of Water Treatment Plants.

B. American Society of Mechanical Engineers (ASME):

1. B1.20.1, Pipe Threads, General Purpose, Inch.

2. B16.1, Cast Iron Pipe Flanges And Flanged Fittings.

3. B16.3, Malleable Iron Threaded Fittings.

4. B16.5, Pipe Flanges and Flanged Fittings.

5. B16.9, Factory-Made Wrought Steel Buttwelding Fittings.

6. B16.11, Forged Fittings, Socket-Welding and Threaded.

7. B16.15, Cast Bronze Threaded Fittings, Classes 125 and 250.


8. B16.18, Cast Copper Alloy Solder Joint Pressure Fittings.

9. B16.22, Wrought Copper and Copper Alloy Solder Joint Pressure Fittings.

10. B16.24, Cast Copper Alloy Pipe Flanges & Flanged Fittings: Class 150, 300,400, 600, 900, 1500 & 2500.

11. B16.26, Cast Copper Alloy Fittings for Flared Copper Tubes.

12. B16.28, Wrought Steel Buttwelding Short Radius Elbows And Returns.

13. B16.36, Orifice Flanges.

14. B16.42, Ductile Iron Pipe Flanges and Flanged Fittings: Classes 150 and 300.

15. B16.47, Large Diameter Steel Flanges.

16. B31.5, Refrigeration Piping.

17. B31.9, Building Services Piping.

18. B36.10, Welded and Seamless Wrought Steel Pipe.

19. B36.19, Stainless Steel Pipe.

C. American Society for Testing and Materials (ASTM):

1. D2855, Standard Practice for Making Solvent-Cemented Joints with Poly (Vinyl Chloride) (PVC) Pipe and Fittings.

2. B280 Specification for Seamless Copper Tube for Air Conditioning and Refrigeration Field Service.

D. Air Conditioning, Refrigeration and Heating Institute (ARI):

1. 495, Refrigerant Liquid Receivers.

2. 710, Liquid Line Dryers.

3. 730, Flow Capacity Rating and Application of Suction Line Filters and Filter-Driers.

4. 750, Thermostatic Refrigerant Expansion Valves.

5. 760, Solenoid Valves for Use with Volatile Refrigerants.

E. American Society of Heating, Refrigeration and Air-Conditioning Engineers(ASHRAE):


1. 15, Safety Standard for Refrigeration Systems.

2. 34, Number Designations of Refrigerants.

F. Manufacturers' Standardization Society (MSS):

1. SP-25, Standard Marking System for Valves, Fittings, Flanges and Unions.

2. SP-58, Pipe Hangers and Supports - Materials, Design and Manufacture.

3. SP-69, Pipe Hangers and Supports - Selection and Application.

4. SP-89, Pipe Hangers and Supports - Fabrication and Installation.

G. Pipe Fabrication Institute (PFI):

1. ES-3, Fabricating Tolerances.

2. ES-4, Hydrostatic Testing of Fabricated Piping.

3. ES-24, Pipe Bending Methods, Tolerances, Process and Material Requirements.

H. Title 24, Part 5, California Plumbing Code, Latest Edition.


PART 2 - PRODUCTS

2.1 STEEL PIPE, AND STEEL AND IRON FITTINGS, [STL]

PIPE Materials,Manufacture & Testing:

NPS 24” and Smaller:

ASTM A53, Type E or S, Grade B.

NPS 48” and Smaller:

ASTM A106-S1, Grade B.

52” and Larger: API 5L-2004, Grade B, PSL 2. See API 5L Stipulations hereinafter.

Construction / Dimensions:

NPS 48” and smaller: ASME B36.10, Standard weight (unless otherwise shown)

52” and larger: Steel cylinder OD, wall thickness, lining and coating as shown on the drawings. See API 5L Stipulations hereinafter.

FITTINGS Materials,Manufacture & Testing::

Manufactured Fittings:

Wrought Steel: ASTM A234, Grade WPB.

Forged Steel: ASTM A105, Grade B.

Cast Iron for Fittings: ASTM A48 Class tensile strengths by fitting size as required per AWWA C110.

Ductile Iron for Fittings: ASTM A536 (all Grades).

Malleable Iron for Fittings: ASTM A197.

Fabricated Fittings:

Steel Plate for AWWA C208 fittings: ASTM A36; or ASTM A283 Grade D; or ASTM A1011-SS Grade 36; or A1018-SSGrade 36.


Manufactured Fittings:

Wrought Steel Buttweld Fittings: ASME B16.9.

Forged Steel Fittings: ASME B16.11.

Wrought Steel Short Radius Elbows: ASME B16.28

Flanged Ductile Iron and Gray Iron Fittings, 3” to 48”: AWWA C110-08, ASME B16.42, class as shown

Malleable Iron Threaded Fittings, 2” and smaller: AMSE



B16.3, class 150 unless otherwise shown.

Fabricated Fittings:

AWWA C208 and per the drawings.

FLANGES Materials: ASME Steel Forgings: ASTM A105 Grade B, or, ASTM A182 Grade F2.

AWWA Steel Forgings: ASTM A105 Grade B, or, A181Class 70.

AWWA Steel Plate: ASTM A36; ASTM A516 grade 65 or 70; or ASTM A283 Grade D; or ASTM A1011-SS Grade 36; or A1018-SS Grade 36.


Service pressures 175 psig and under: All flanges shall be flat faced and as specified herein unless otherwise shown.

ASME Slip-On or Welding Neck Type, NPS 24” and smaller: ASME B16.5, Class 150 unless otherwise shown.

ASME Welding Neck Type, NPS 26” thru 60”: ASME B16.47, Series A, Class 150 unless otherwise shown.

AWWA Steel Forged or Plate Flanges, 12” and smaller: AWWA C207-07, Class D unless otherwise shown.

AWWA Steel Forged or Plate Flanges, 16” and larger: AWWA C207-07, Class D unless otherwise shown. (150 psig max service pressure)

Refer to Standard Drawing 323-EA.


ASME Slip-On or Welding Neck Type, NPS 24” and smaller: ASME B16.5, Class 150 unless otherwise shown.


AWWA Steel Forged or Plate Flanges, 108” and smaller: AWWA C207-07, Class E unless otherwise shown.


Service pressures from above 275 psig to 600 psig maximum: All flanges shall be raised face and as specified herein unless otherwise shown.

ASME Slip-On or Welding Neck Type, NPS 24” and



smaller: ASME B16.5, Class 300 unless otherwise shown.



Marking Requirements: Refer to “Fittings, Flange and Union Markings” hereinafter.

Orifice Flanges: ASME B16.36

END OF [STL]

2.2 GALVANIZED STEEL PIPE, [GST]


2-inch and smaller: ASTM A53 per [STL]

Hot-dip galvanize all pipe per ASTM A53 - “Galvanized Pipe”.


2-inch and smaller: Same as [STL]

FITTINGS Materials: Malleable Iron Threaded Fittings, 2” and smaller: ASTM A197; Hot-dip galvanize all fittings per ASTM A153.


Malleable Iron Threaded Fittings, 2” and smaller: ASME B16.3, Class 150 unless otherwise shown.

END OF [GST]


2.3 STAINLESS STEEL PIPE AND FITTINGS, [SST]


ASTM A312(-S1 for over 2-inch NPS)

ASTM A358 Class 2(-S1-S2 for over 2-inch NPS)

ASTM A376(-S1 for over 2-inch NPS).

Pipe shall be either seamless or have a single longitudinal (straight) seam weld.

All pipes shall be cleaned, de-scaled and passivated per ASTM A380 and A967.

Threaded Joints: Grades TP304 or TP316 as shown.

Welded Joints: Grades TP304L or TP316L


ASME B36.19, SCH 40S unless otherwise shown

FITTINGS Materials,Manufacture & Testing::

ASTM A182:

Threaded: Grades F304 or F316 as shown.

Welded: Grades F304L or F316L as shown.

ASTM A403:

Threaded: Grades WP304 or WP316 as shown.

Welded: Grades WP304L or WP316L as shown.

All fittings shall be cleaned, de-scaled and passivated per ASTM A380 and A967.

Construction / Dimensions :

Wrought Buttweld Fittings: ASME B16.9.

Forged Fittings:

ASME B16.11, Class 3000 unless otherwise shown.

MSS SP-114-2007, when Class 150 fittings are shown.

Wrought Short Radius Elbows: ASME B16.28


2.3 STAINLESS STEEL PIPE AND FITTINGS, [SST]

FLANGES Materials: ASTM A182 Grade F304 or F316



Steel Plate Flanges, 12” and smaller: AWWA C207-07, Class D unless otherwise shown.

Plate Flanges, 16” and larger: AWWA C207-07, Class D unless otherwise shown. (150 psig max service pressure)


Service pressures 275 psig and under: All flanges shall be flat faced and as specified herein unless otherwise shown. If grade 304L or 316L is used, the maximum pressure rating is de-rated to 230 psig.

Slip-On or Welding Neck Type, NPS 24” and smaller: ASME B16.5, Class 150 unless otherwise shown.

Welding Neck Type, NPS 26” thru 60”: ASME B16.47, Series A Class 150 unless otherwise shown.

Plate Flanges, 108” and smaller: AWWA C207-07, Class E unless otherwise shown.


Service pressures from above 275 psig to 600 psig maximum: All flanges shall be raised face and as specified herein unless otherwise shown.

Slip-On or Welding Neck Type, NPS 24” and smaller: ASME B16.5, Class 300 unless otherwise shown.

Welding Neck Type, NPS 26” thru 60”: ASME B16.47, Series A Class 300 unless otherwise shown.


Marking Requirements: Refer to “Fittings, Flange and Union Markings” hereinafter.

Orifice Flanges: ASME B16.36

END OF [SST]


2.4 STAINLESS STEEL INSTRUMENT TUBING, [SSI]

PIPE

Materials: ASTM A269, Grade TP 304L or TP 316L, Rockwell B Hardness 80 or less


Tube OD (in) Tube Wall Thickness (in)

1/8 0.028

3/16 0.035

¼ 0.035

3/8 0.035

FITTINGSMaterials: 316 Stainless Steel


Double Ferrule Compression Fittings (see Manufactured Fittings below).

INSULATION Materials & Construction

Per Section 40 42 13.10.

END OF [SSI]


2.5 PVC PIPE AND FITTINGS, [PVC]

PIPEMaterials: ASTM D1784, Class 12454-B

Construction / Dimensions: ASTM D1785, Schedule 80 unless otherwise shown

JOINTS

Solvent-welded using:

Primer per ASTM F656; See “Miscellaneous Components” for acceptable products.

Solvent cement per ASTM F493; See “Miscellaneous Components” for acceptable products.

Threaded Connections: use only where connecting to unions, valves, and equipment that may require future disassembly, and as shown on the drawings.

Threaded Sealing Compound: Polytetrafluoroethylene (PTFE). See “Miscellaneous Components” for acceptable products.

Flanges

Van Stone type (Two-Piece), 150-psi @ 73degF rating unless otherwise shown. Van Stone flanges 2-inch and larger shall have a solid plastic ring of continuous thickness with no depressions or other thickness reductions.

FITTINGSMaterials: (same as pipe)


Socket: ASTM D2467

Threaded: ASTM D2464

IDENTIFICATION SYSTEM

Above ground: ID markers per section 22 05 53.05.

Underground: Pipe tracer wire and marking tape per Section 33 12 28.11.

END OF [PVC]


2.6 COPPER TUBING AND FITTINGS, [CU]

PIPE Materials:

General water service: Type K, hard temper (no coils), ASTM B88

Buried water service: Type K, hard temper or coils, ASTM B88, blue polyethylene coating of 0.025-inch min thickness.Acceptable products: Mueller PlumbShield, Kamco Aqua-shield, or equal as approved by the Engineer.

Instrument service: seamless per ASTM B75, 050 (lightly annealed) temper.

FITTINGS

Materials:

Wrought copper or bronze, socket type: ASTM B75

Compression: Brass

Flared: Brass


Cast Soldered, ASME B16.18

Wrought Soldered: ASME B16.22

Compression: See Manufactured Fittings below

45–degree Flared: See Manufactured Fittings below

FLANGES


Cast flat-faced, ASME B16.24, Class 150 (unless otherwise shown)

Materials : ASTM B61 alloy C92200 or B62 alloy C83600.

JOINTS Construction: Soldered: per ASTM B828

SOLDERMaterials: ASTM B32, Type Sn95, Sn94, E, AC, AM or WS – Solid core

only. 0.20% maximum lead content.

END OF [CU]


2.7 BRASS PIPE AND FITTINGS, [BRS]

PIPEMaterials: ASTM B43

Construction / Dimensions: ASTM B43, Regular

FITTINGSMaterials: Threaded Bronze: ASTM B62

Construction / Dimensions: ASME B16.15, Class 125 unless otherwise shown.

END OF [BRS]

2.8 API 5L STIPULATIONS

A. Where API 5L pipe is specified, the following stipulations shall apply:

1. Product Specification Level (PSL) 2 and all the related requirements.

2. The manufacturing process shall be limited to one of the following:

a. Seamless

b. Electric Welding with Filler Material:

1) Submerged-arc single longitudinal (straight) seam weld.

2) Gas Metal-arc single longitudinal (straight) seam weld.

c. Electric Resistance Welding without filler material, single longitudinal (straight) seam weld, with post-weld heat treatment.

3. No jointer welds allowed.

4. Certificate of compliance, with test results.

5. Fracture toughness tests.

6. Ultrasonic or electromagnetic examination of welds.

7. Hydrostatic tests.

8. Marking requirements.


9. Purchaser inspection at both the pipe manufacturing plant and piping fabrication facility.

2.9 FITTING, FLANGE AND UNION MARKINGS

A. All fittings, flanges and unions used in piping connections which include (but are not limited to) flanged, soldered, brazed, threaded, or welded joints, shall be marked to identify the manufacturer, the rating description, materials of construction, and service limitations per MSS SP-25. Components not stamped with the markings per this requirement will be rejected.

2.10 PLASTIC TUBING, HOSE AND FITTINGS

A. Nylon Reinforced:

1. Tube: Clear PVC.

2. Reinforcement: Nylon braid within tube wall.

3. Temperature: 25 to 150 degrees Fahrenheit.

4. Working pressure rating at 70 deg F:

a. ¾” and under: 150 psi, minimum.

b. 1” and 1-¼”: 100 psi, minimum.

c. 1-½” and 2”: 70 psi minimum.

5. Standards: NSF 51 listed food grade resin.

6. Ends: Socket or NPT by barb, polypropylene.

7. Clamps: SST.

8. Acceptable products: Finger Lakes BraidFlex 70N, Nalgene 980, Tygon B-44-4X, Thermoplastic Processes Excelon Braided, or equal as approved by the Engineer.

B. Non-reinforced, 1” ID and Smaller:

1. Clear flexible PVC.

2. Wall thickness as required to meet or exceed maximum system pressure at point of installation.

3. Acceptable products: Nalgene 180, Excelon RNT, Finger Lakes GP70 or equal as approved by the Engineer.


C. Vacuum Tubing, 1” ID and Smaller:

1. Clear flexible plastic with extra heavy wall thickness.

2. Rated for full vacuum, 29.9 in-Hg @ 73 deg F.

3. Acceptable products: Tygon R-3603, Nalgene 180 Vacuum, or equal as approved by the Engineer.

D. Barbed Tube Fittings, For 1” ID Tube and Smaller:

1. PVC, polypropylene, polyethylene, acetal, or nylon construction.

2. Multi-barb tube end and NPT end as required.

3. With all stainless steel or plastic hose clamps.

4. Acceptable products: Herco 700 series, Parker Hannifin TrueSeal, or equal as approved by the Engineer.

E. Braided Metal Hose:

1. Service: Cooling Water.

2. Seam welded annular corrugated metal hose.

3. Material: Bronze or stainless steel construction as shown on the drawings.

4. Ends: Flanged, threaded or plain as shown on the drawings.

5. Working pressure shall meet or exceed the system requirements.

6. Reinforcement: Single or double metal braid as required to meet the working pressure requirements.

7. Acceptable products: Metraflex, Hyspan, or equal as approved by the Engineer.

2.11 MANUFACTURED FITTINGS

A. Specialty Couplings: See Section 33 11 07 for the following coupling types:

1. Flexible Pipe Couplings.

2. Grooved Pipe Couplings.

3. Flanged Coupling Adapters.

4. Flexible Expansion Joints.


5. Flexible Ball-Type Expansion Joints.

B. Threaded Outlet: 3000 lb., materials same as pipe. Acceptable products: Grinnell Fig. 1812; Threaded Trans-O-Con, Phoenix Forging Co.; Bonney Forge Thred-O-let; or equal as approved by the Engineer.

C. Welding Outlet: Standard weight, materials same as pipe. Acceptable products: Grinnell, Fig. 1811; Bonney Forge Weldolet; or equal as approved by the Engineer.

D. Stub-end flanges and backing rings: Type 304L stainless steel. Acceptable products: Alaskan Copper Works Fig SK38P, or equal as approved by the Engineer.

E. Tube Fittings:

1. Compression Tube Fittings (Instrument Service): Double-ferrule type, brass or stainless steel as shown. Acceptable products: Swagelock Gageable Tube Fittings, Parker Hannifin A-Lok Tube Fittings, or equal as approved by the Engineer.

2. Flared 45 deg Tube Fittings (General Water Service): Brass per AWWA C800-05. Acceptable products: Mueller Co., AY McDonald Mfg., or equal as approved by the Engineer.

F. Unions:

1. PVC Unions:

a. SCH 80 PVC; socket by socket; Viton O-ring seals for all services except caustic (CA) and ammonia (NH). Use EPDM O-rings for CA and NH services.

b. Acceptable products: Spears Manufacturing Co., Ryan Herco, or equal as approved by the Engineer.

2. Transition Unions, 2-Inches and Smaller:

a. Socket SCH 80 PVC by FNPT brass union (substitute type 316 stainless steel where shown on the drawings), with EPDM O-ring seal.

b. Acceptable products: Spears Manufacturing Co., Ryan Herco, or equal as approved by the Engineer.

3. Dielectric Unions, 2-Inches and Smaller:

a. Rated 250 psi, socket end copper or FPT end brass to FPT end steel, steel nut with dielectric insulators and EPDM gasket; breakdown voltage of 600 volts, minimum.


b. Acceptable products: A.Y. McDonald Mfg, Wilkins, or equal as approved by the Engineer.

G. Transition Couplings, 2-Inches and Smaller:

1. Socket SCH 80 PVC by FNPT brass (substitute type 316 stainless steel where shown on the drawings), with EPDM O-ring seal.

2. Acceptable products: Spears Manufacturing Co., Ryan Herco or equal as approved by the Engineer.

H. Flange Insulation Sets: See Section 05 05 26.

2.12 MODULAR MECHANICAL SEALS

A. Size:

1. To match pipe shown on the drawings.

2. Contractor shall coordinate the size of the wall (or floor) opening, in accordance with manufacturer’s recommendations.

3. When it is required to insert a flange through the penetration, size seal and penetration to accommodate.

B. EPDM synthetic rubber seal links with composite pressure plate and stainless steel hardware.

C. Designed to be leak tight with 20 psig static pressure.

D. Acceptable Products:

1. Thunderline Link-Seal, Model S-316 Series.

2. Proco Products Pen-Seal Series.

3. Metraflex Metraseal Type ES Series.

4. Or equal as approved by the Engineer.

2.13 STEEL WALL SLEEVE FOR MODULAR MECHANICAL SEAL

A. Carbon steel sleeve with 2-inch water stop collar at mid-point. OD to match the modular mechanical seal model and pipe size requirements. Thickness to match standard weight pipe. Length to match wall thickness. Water stop collar connected by a continuous weld bead on both sides. Fusion bonded lined and coated per Section 09 96 56.10.

B. Acceptable Products:


1. Thunderline Century-Line WS Series.

2. Proco Products Pen-Seal Wall Sleeve Series.

3. Metraflex Wall Sleeve.

4. Or equal as approved by the Engineer.

2.14 PIPE SUPPORT SYSTEMS

A. General:

1. All piping shall be supported as specified herein and as shown on the drawings. Manufacturer's catalog figure numbers are typical of the types and quality of standard pipe supports and hangers to be employed. Special support and hanger details are shown to cover typical locations where standard catalog supports are inapplicable.

2. All piping hangers, supports, rods, clamps, guides, and other hanger and support accessories shall be stainless steel unless otherwise shown or specified.

3. Horizontal piping larger than 2 inches: Pedestal type saddle with u-bolt in accordance with Standard Drawing 9944-GB, unless otherwise shown.

B. Hangers:

1. Clevis Type:

a. Materials: Carbon steel, hot dipped galvanized.

b. MSS SP 58, Type 1 or 6.

c. Acceptable products: Grinnell, Figure 104 or 260; B-Line, Figure B3198 or B3100; Piping Technologies and Products, PTP Figures 83, 89, 110;Tolco Figure 1; or equal as approved by the Engineer.

2. Hanger Rods, Clevises, Nuts, Sockets, and Turnbuckles: In accordance with MSS-SP-58.

3. Attachments:

a. I-Beam Clamp: Concentric load type, MSS SP 58, Type 21, 28, 29, or 30, which engage both sides of flange.

b. Concrete Inserts: MSS-SP-58, Type 18, continuous channel insert with load rating not less than that of hanger rod it supports.

c. Concrete Rod Attachment Plate: Steel plate with four-anchor ceiling attachment and rod U-lug. Acceptable products: Piping Technologies and


Products, PTP Fig. 73; Grinnell, Fig. 52; Bergen-Paterson, Part 1020-Type 1; Tolco Figure 35; or equal as approved by the Engineer.

C. Wall Brackets:

1. Material: carbon steel with galvanized finish, or stainless steel.

2. MSS SP-58, Type 31 light loading, Type 32 medium loading, or Type 33 heavy loading, as required.

3. Acceptable products: Anvil Figures 194, 195 or 199; Cooper B-Line Figures B3063, B3605 or B3607; Tolco Figures 30L, 30M 0r 30H, or equal as approved by the Engineer.

D. Pipe Riser Support:

1. Materials: Carbon steel. Provide stainless steel inside reservoirs as shown.

2. Coatings: hot-dipped galvanized. Provide PVC coating inside reservoirs as shown.

3. MSS-SP-58, Type 8.

4. Acceptable products: Piping Technologies and Products, PTP Figure 90; Grinnell figure 261 series, Tolco Figure 6, or equal as approved by the Engineer.

E. Pipe U-bolts:

1. Materials: Carbon steel, hot dipped galvanized or 316L stainless steel as shown.

2. MSS-SP-58 Type 24, standard loading, with single hex nuts on pipe side, dual hex nuts on opposite side, and washers both sides.

3. Acceptable products: Pipe Shields Inc, G Series; Tolco Figure 110; or equal as approved by the Engineer.

F. Anti-friction Pads:

1. Pads: All TFE construction, ¼” thickness, virgin grade. Etched one side for surface bonding.

2. Bonding Agent: High-temperature TFE bonding epoxy cement. 250 deg F temperature rating, minimum.

3. Acceptable products: Piping Technologies and Products; Tolco Figure 425; or equal as approved by the Engineer.


G. Channel Strut:

1. Materials: Type 316 stainless steel unless otherwise shown.

2. Channel Size: 12 gauge, 1-5/8" by 1-5/8", unless otherwise shown.

3. Members and Connections: Design for all loads with safety factor of 5.

4. Provide compatible stainless steel channel nuts, bolts, pipe clamps, brackets, and hardware as required.

5. Provide pipe clamp isolators as follows:

a. Flexible elastomer pipe clamp isolators that are preformed to the pipe OD for PVC and copper piping. Provide for other piping materials when isolator or cushion is shown on the drawings. Isolators cut from strip material are not acceptable. Acceptable products: Unistrut “Cush-a-clamp”, B-Line “BVT Series Vibraclamp”, Anvil “Cush-a-clamp” or equal as approved by the Engineer.

6. All exposed ends of metal framing system channels shall be provided with end caps.

7. Acceptable Products: Cooper B-Line B22SS6, Unistrut P1000SS or F1000, Anvil-Strut AS-200, or equal as approved by the Engineer.

H. Channel Strut Cantilever Bracket, Single Top Bolt: Horizontal 12 gauge 316stainless steel strut with integral vertical strut mount. Slot facing up. Top or top and bottom bolt hole(s). Length of 6”, 12”, 18” or 24” as required. Acceptable products:Cooper B-Line B196 and B198, Unistrut P2231 thru P2234, Anvil-Strut AS-661-T1, or equal as approved by the Engineer.

I. Channel Strut Cantilever Bracket, Top and Bottom Bolt: Horizontal 12 gauge 316 stainless steel strut with integral vertical strut mount. Slot facing up. Top or top and bottom bolt hole(s). Length of 6”, 12”, 18” or 24” as required. Acceptable products: Cooper B-Line B196 and B198, Unistrut P2944 thru P2947, Anvil-Strut AS-661-T1, or equal as approved by the Engineer.

J. Channel Strut Concrete Inserts:

1. Materials: Type 316 stainless steel.

2. Maximum Allowable Point and Uniform Load: 2,000 lbs.

3. Maximum Anchorage Spacing: 4-inches.

4. Embed Depth: 3-Inches.


5. Length as required.

6. Acceptable products: Unistrut Series P3249-3270, Cooper B-Line B22-I,series, Anvil-Strut, or equal as approved by the Engineer.

K. Sway Strut:

1. Adjustable length steel strut.

2. Three-bolt pipe clamp, MSS SP-58, Type-3.

3. Mounting brackets.

4. Acceptable products: Piping Technologies and Products; Anvil Fig. 640; Bergen-Paterson, Part 2250/6252; or equal as approved by the Engineer.

L. Concrete Anchors and Anchor Bolts: Section 05 50 00.

2.15 FACTORY FINISHING

A. In accordance with Section 33 10 01 and the “Finish, Coating and Color Schedule” as shown on Drawing 2117-Z-001.2

B. Holdbacks at field joints:

1. Cement-Mortar: As necessary for field weld.

2. Fusion-Bonded Epoxy: 6-inch from field weld joints.

2.16 MISCELLANEOUS COMPONENTS

A. Strainers and Filters: See Section 33 12 27.11.

B. Tape Wrap and Wax-Tape Wrap: See Section 33 10 01.

C. Bolt Thread Anti-Seize Compound: See Section 05 05 26.

D. Thread Sealants

1. For Stainless Steel Piping:

a. Suitable for operating pressures up to 10,000 psig.

b. NSF/ANSI 61 approved.

c. Acceptable products: Loctite® 565, Real-Tuff by Hercules, or equal as approved by the Engineer.

2. For Thermoplastic Piping: Polytetrafluoroethylene (PTFE) thread tape.


E. Flange Gaskets: See Section 05 05 26.

F. PVC and CPVC Joint Sealers

1. Solvent-welded primer:

a. Per ASTM F-656.

b. NSF approved.

c. Acceptable products: IPS Corporation Product P-70, Cookson Company “E-Z Weld” Product 212, Oatey “Purple NSF”, or equal as approved by the Engineer.

2. Solvent cement:

a. Per ASTM F-493.

b. NSF approved.

c. Rated as industrial grade and specifically for chemical process applications.

d. Rated for all pipe classes and schedules through 12” diameter.

e. Heavy bodied, medium set time.

f. Acceptable products: IPS Corporation Product 724, IPEX XIRTEC 24, or equal as approved by the Engineer.

3. Thread sealing compound:

a. Polytetrafluoroethylene (PTFE).

b. Acceptable products: Whitlam Co. “Power Seal PTFE”, Hercules “Real-Tuff”, or equal as approved by the Engineer.

G. Pipe Insulation: See Section 33 12 28.11

H. Pipe Identification

1. Provide identification per Section 22 05 53.05, Pipe Identification.

PART 3 - EXECUTION

3.1 INSPECTION

A. Expense of re-witnessing failed hydrostatic tests or re-inspection of any phase of pipe manufacture shall be paid by the Contractor.


B. Expense of re-witnessing or re-inspection by the District's authorized agent shall be the total charge billed to the District by the agent.

3.2 SHOP FABRICATION

A. Tolerances:

1. Tolerances shall be per PFI Standard ES-3 and as follows:

a. Linear Dimensions (intermediate or overall), including: face-to-face, face-to-end, and end-to-end of straight piping; center-to-end or center-to-face of nozzles and other attachments; or center-to-face of bends. Tolerances are not accumulative.

1) Refer to Figure 1 in PFI ES-3 for illustration.

2) 10-inch and smaller: +/- 1/8-inch maximum

3) 12-inch thru 24-inch: +/- 3/16-inch maximum

4) 24-inch thru 36-inch: +/- ¼-inch maximum

5) Larger than 36-inch: _+/- ¼-inch plus +/- 1/16-inch for each 12-inches over 36-inch.

b. Angularity:

1) Refer to Figure 1 in PFI ES-3 for illustration.

2) Alignment of flange facings or pipe ends shall not deviate by more than 3/64-inch per foot or 1/32-inch total, whichever is greater.

3) End preparation for field buttwelds shall not shall not deviate by more than 1/32-inch per foot across the land for inert gas weld or 3/32-inch for other welds.

4) Rotation of flanges shall be 1/16-inch maximum.

B. Stainless Steel Piping

1. Larger than 2-inch pipe joints: Shop welded stainless steel pipe joints, including the entire heat-affected zone, shall be cleaned, de-scaled and passivated per ASTM A380 and A967. Both the exterior and interior of the joint shall be treated. Inaccessible interior joints, as approved by the Engineer, shall be omitted from this process

2. 2-inch and smaller pipe joints: Shop welded stainless steel pipe joints shall be passivated as above when called out on the drawings.


3.3 INSTALLATION - GENERAL

A. Dimensions given on drawings are nominal. Allowances for gaskets and welds are not shown and shall be provided. Existing pipe spool lengths shall be verified prior to fabrication. The locations and elevations of connection points to existing pipes shall be verified prior to piping fabrication.

B. Tolerances:

1. Unless otherwise noted, the pipe installation tolerances shall be:

a. Process Pipe:

b. Plumb: +/- 3/64-inch/foot maximum from vertical.

c. Level: +/- 3/64-inch/foot maximum from either level or the designed slope when a slope is required.

d. Elevation: +/- 01/8-inch maximum from the design elevation.

2. Prior to bolt-up, flanges shall be parallel within 1/16-inch/foot measured across any diameter and the bolt holes shall be aligned within 1/8-inch maximum offset.

C. Clean out fittings, valves, and pipe sections before installing.

D. Make up welded steel flanged joints as shown on Standard Drawing 323-EA,324-EA, or 325-EA as appropriate. Remove all traces of protective coatings, dirt or other foreign material from both flange faces before final assembly.

E. Furnish and assemble pipe and fittings to provide accurate alignment for joints:

1. Make joints watertight.

2. Use an anti-seize compound on all bolt threads. Follow manufacturer's instructions for application.

F. Provide temporary watertight plugs or bulkheads for closure of the open ends of piping when pipe-laying operations are not in progress, to prevent the entry of rodents or other contaminants.

G. Pipes and fittings shall be free from tool marks.

H. Field measure, fit, and secure piping without forcing or springing. Flanged pipe spools shall be re-fabricated as required for proper fit-up.

I. Piping connections shall not impart stress or strain to equipment.


J. The use of spacers between flanges for the purpose of correcting pipe spool length errors shall not be permitted. The appropriate pipe spool, as approved by the Engineer, shall be re-fabricated or replaced as required to provide direct flange fit-upwithout the use of spacers.

K. No punched strap, wire, or other makeshift devices will be accepted.

L. Joints and Connections: Cut piping and tubing square. Remove rough edges and burrs from both the outside and inside edges and ream to original diameter.

M. Unless otherwise shown, install piping parallel to walls and structures neatly both as to workmanship and grouping.

N. Run pipes in the approximate locations and sized as shown on the drawings. Offset piping wherever necessary to obtain headroom and as approved by the Engineer.

O. Caulk watertight around pipes passing through walls.

P. Changes in sizes of piping shall be made with reducing fittings wherever they occur. Unless otherwise shown, the use of bushings will not be permitted. Use eccentric reducing fittings where necessary to provide free drainage of lines.

Q. Pipe and Tube Bending: Pipe and tubing bend radius shall conform to PFI Standard ES-24 and SAE-SA33611. The preferred bend radius is 4D, or 4 times the tube nominal diameter. The minimum bend radius shall be 3D. Bends of a smaller radius than 3D shall be pre-approved by the Engineer. Bends shall be smooth and accurate without significant kinking, wrinkling or flattening of the tube. Wrinkle depth on the inside radius of the bend shall not exceed 2 percent of the tube OD. Scratches in the bend shall not exceed 10 percent of the tube wall thickness. The type of bending tool or bending machine used shall be approved for the material type, size and wall thickness of the tube to be bent.

R. High and Low Points: Do not route piping in such a manner that high points and low points are created, except as approved by the Engineer. Refer to article 3.3.C. for exposed piping vent and drain requirements.

S. Threaded Joints:

1. Conform to ASME B1.20.1.

2. Produce sufficient thread length to ensure full engagement when screwed home in fittings.

3. Countersink pipe ends, ream and clean chips and burrs after threading.

4. Make connections with not more than three threads exposed.

5. Lubricate male threads with Teflon tape (except stainless steel piping).


6. Apply thread sealant on stainless steel piping.

7. Cutting oils used for threaded piping shall be NSF61 certified, or food-grade when the piping is in contact with drinking water.

T. Modular Mechanical Seals:

1. When modular mechanical seals are required, the Contractor shall determine the appropriate wall or floor opening size suitable for the selected seal. When it is required to insert a flange through the penetration, the seal and penetration shall be sized to accommodate.

2. Seal bolt heads shall face toward the structure interior.

3. Buried Service: Seal annular space around pipe on buried side of seal with polyurethane sealant.

4. See typical detail TM030 for additional installation requirements.

U. Hydraulic Instrumentation and Control Tubing:

1. Do not scratch outside surface of tubing.

2. Deburr tube ends before installing connector.

3. Install connectors per manufacturer’s instructions.

4. Install instrumentation tubing to such a slope as to be self-venting of air.

V. Copper Tubing:

1. Cutting in or swaging and expanding copper joints will not be tolerated.

2. Install pre-formed elastomeric insulating cushions between copper pipe and pipe support clamps.

3. Compression Joints – prepare tubing ends per fitting manufacturer’s written instructions.

4. Flared fitting joints for general water service: Flare tubing end at 45 degrees with approved flaring tool.

W. PVC and CPVC Piping:

1. All Contractor’s personnel installing PVC and CPVC pipe materials shall be trained and certified by the PVC pipe/fitting manufacturer’s representative.

2. All pipe and fittings shall be handled, stored, and inspected in accordance with the pipe manufacturer's recommendations.


3. All pipe and fittings shall be stored out of direct sunlight and away from heat prior to installation. Covering with only a tarpaulin is not acceptable.

4. All piping shall be cut, made up, and installed in accordance with the pipe manufacturer's recommendations, ASTM D 2855, and this Section.

5. All burrs shall be removed and all shavings cleaned from inside of the pipe prior to joining.

6. Use strap wrench for tightening threaded plastic joints. Do not over-tighten fittings.

7. Install plastic pipe and tubing to permit contraction and expansion from temperature changes without damage.

8. Minimize the use of threaded joints in plastic piping systems.

9. Do not install pipe when ambient temperatures are below 40 degrees F, nor above 90 degrees F when exposed to direct sunlight. Shield ends to be joined from direct sunlight prior to and during joining.

10. Provide adequate ventilation when working with pipe solvent cements.

11. Use flange or transition union connections when transitioning from PVC or CPVC piping to metallic piping whenever possible (whether shown on the drawings or not). Use transition couplings where flanges or transition unions are not practical. Use PVC or CPVC male threaded adapters where threaded connections are required.

12. Flange nuts shall be torqued in accordance with the gasket manufacturer's recommendations. Do not over-torque gasketed flanges.

13. Outdoor exposed plastic piping shall be coated with a white urethane UV topcoat per Section 09 96 56.05, High Build Epoxy Coatings.

14. All Contractor’s personnel installing PVC and CPVC pipe materials shall be trained and certified by the PVC pipe/fitting manufacturer’s representative.

15. Install pre-formed elastomeric insulating cushions between plastic pipe and pipe support clamps.

X. Braided Metal Hose:

1. Install per manufacturers instructions.

2. Install without offset, tension, compression or torque applied to hose.


3. Install with the axis of the hose at a right angle to the any motion at the point of connection.

4. Install support for hose at the end of the hose length.

5. When bends are required, the bend shall not be smaller than the minimum bend radius required by the manufacturer.

Y. Stainless Steel Piping

1. Larger than 2-inch pipe joints: Field welded stainless steel pipe joints, including the entire heat-affected zone, shall be cleaned, de-scaled and passivated per ASTM A380 and A967. Both the exterior and interior of the joint shall be treated. Inaccessible interior joints, as approved by the Engineer, shall be omitted from this process

2. 2-inch and smaller pipe joints: Field welded stainless steel pipe joints shall be passivated as above when called out on the drawings.

3.4 INSTALLATION - EXPOSED PIPING

A. Unions:

1. Provide at each piping connection to equipment or instrument (whether shown on the drawings or not) on equipment or instrument side of each isolation valve to facilitate installation and removal.

2. At each valved header tap, provide a union after the tap valve.

3. Some isolation valves have integral unions in which case additional unions are not required.

B. Piping Clearances (unless otherwise shown):

1. Do not route piping in front of, or to interfere with access ways, ladders, stairs, platforms, walkways, openings, doors, hatches, or windows.

2. Do not route piping over, around, in front of, or in back of electrical equipment including controls, panels, switches, terminals, boxes, or other similar electrical work.

3. Cutouts for pipe penetrating through grating shall be in accordance with the following:

a. Grating cutout diameter:

PIPE NOMINAL SIZE GRATING CUTOUT DIAMETER


¾” through 3” 1” larger than Pipe Nominal Size

4” through 8” 2” larger than Pipe Nominal Size

b. A group of pipes that penetrate through grating at a wall surface may have a continuous cutout that is parallel to the wall surface provided that at no point shall the gap between pipe and grating exceed 2-inch.

c. Provide banding where called out on the drawings. Banding shall be securely fashioned, free from burrs or rough edges, and of material similar to the grating.

C. Vents and Drains: Provide ½” vent taps at all high points and ¾” drain taps at all low points. Taps shall include a threaded ball valve for isolation. Valves shall be of the appropriate material and pressure rating. Steel taps shall be per TM002; stainless steel shall be similar. Copper and PVC taps shall use reducing tees.

3.5 INSTALLATION - BURIED PIPE

A. Joints: Do not encase joints in concrete unless specifically shown, or approved in writing by the Engineer.

B. General Placement:

1. In accordance with Section 31 23 16 and as shown on the drawings.

2. Keep trench dry until pipe laying and joining is complete.

3. Excavate trench bottom and sides of ample dimensions to permit visual inspection and testing of entire pipeline.

4. Close and block open end of last laid pipe section when placement operations are not in progress and at close of day's work.

5. Prevent uplift and floating of pipe prior to backfilling.

C. PVC Pipe Placement:

1. Lay pipe snaking from one side of trench to other.

2. Offset: As recommended by manufacturer for maximum temperature variation between time of solvent welding and during operation.

3. Fill with cold water 30 minutes before backfilling.

4. Install tracer wire and marker tape per Section 33 12 28.11.


D. Pipe depth:

1. Pipes within plant site shall have 42” of cover, minimum.

2. Pipes that extend beyond the plant site to “cross country” shall have 48” of cover, minimum.

3. In cases where the pipes must be shallower than the minimum due to interference issues or when called out on the drawings as shallow, a concrete cap shall be provided per TC108.

E. Tape Wrap: All embedded and buried stainless steel, bronze and brass piping, and copper fittings, shall be wrapped with 10 mil PVC tape with a 50 percent overlap, unless otherwise noted.

3.6 PIPE SUPPORT SYSTEMS

A. No attempt has been made to show all required pipe supports in all locations on the drawings. The absence of pipe supports and details on any drawing shall not relieve the Contractor of the responsibility for providing them in accordance with the pipe manufacturer's written recommendations and these specifications.

B. Provide special pipe supports where shown.

C. General support spacing shall be at maximum distances as listed below (unless otherwise shown):

TYPE OF PIPE 1" SIZE AND SMALLER

1-1/4" SIZE AND LARGER

Steel, Stainless Steel, Brass

6' - 0" 10' - 0"

Copper Tubing 5' - 0" 8' - 0"

PVC, CPVC 3' - 0" 5' - 0"

D. Provide at least one pipe support at each change of direction of the pipe.

E. Provide additional pipe supports directly adjacent to valves and other operating devices so that piping does not move when the valve or device is operated.

F. Decrease spacing as necessary to prevent sagging and vibration.

G. Provide a minimum of two anchor bolts on each channel support attached to concrete.


3.7 BOLTING APPLICATION SCHEDULE

A. Unless otherwise noted or shown, all bolting shall be in accordance with Section 05 05 26 and shall be applied according to the following:

BOLT TYPE APPLICATION

Stainless Steel All chemical services

All piping inside vaults, basins, tanks and vessels

All submerged* services

Galvanized steel All other applications

* Submerged is defined herein to mean any portion of the bolted system that can periodically become wetted during operation by the process fluid or ground water.

3.8 NATIONAL ELECTRIC CODE GROUNDING

A. The National Electric Code requires grounding of water piping systems. In order to ensure grounding of bolted flange joints with fusion bonded epoxy or hi-build epoxy coatings the coating under two nuts per flange (four nuts per joint) shall be removed by grinding and special stainless steel lock washers shall be used for these nuts/bolts. After completion of each bolted flange the electrical continuity shall be checked with a volt/ohm meter. Also, when the pipe system has been completed the electrical continuity of the entire pipe system shall be similarly checked.

3.9 CLEANING

A. Liquid Piping Systems:

1. Following assembly, but prior to testing, flush all piping with water at minimum flushing velocities of 2.5 fpm until all foreign matter is removed.

2. If in the opinion of the Engineer flushing large diameter pipe at 2.5 fpm flushing velocity is impractical, clean the piping in-place by other means and then flush the line at lower flushing velocities. The Engineer shall approve all cleaning procedures prior to implementation.

3. Insert cone strainers in flushing connections to attached equipment and leave in-place until cleaning is complete.

4. Remove accumulated debris through drains, or by removing spools or valves from piping as necessary.


B. Gaseous Piping Systems:

1. Blow piping clean using oil free air compressor with dryer. Air shall be dried to a maximum dew point of 40 degrees F.

2. Natural Gas Systems: Purge with nitrogen prior to admitting natural gas.

3.10 DISINFECTION

A. After cleaning but prior to operation, disinfect potable water piping and other piping systems as directed by the Engineer.

B. Disinfection procedures shall be in accordance with AWWA C653-03.

C. Swab or spray the interior of all final connections (piping, fittings and valves) with 1percent hypochlorite solution.

3.11 FIELD FINISHING

A. Notify Engineer at least 3 working days prior to start of any surface preparation or coating application work.

B. See Section 33 10 01 for additional requirements.

C. Fusion-Bonded Epoxy Lining/Coating at Field Joints:

1. Grind lining/coating holdback area at field joints to near-white metal after field joint is made.

2. Abrade lining/coating 6" back from holdback edge to provide adhesion surface for high-build epoxy.

3. Apply high-build epoxy to holdback and abraded areas.

D. Cement-Mortar Linings/Coatings:

1. General:

a. Completed pipeline shall have a sound, continuous, and unbroken coating of reinforced cement mortar.

b. All field girth joints and fittings shall be coated.

c. Damaged original coating shall be repaired.

d. Clean all surfaces to assure adhesion of mortar.

2. Field Joints:


a. Coat after completion and inspection, testing, and District approvals.

b. Do not apply mortar against hot welds.

c. Field applied mortar coating shall be reinforced with self-furring welded wire fabric tack welded to the steel cylinder.

E. Field Finish: Coating of all piping shall be the system and color as designated on the “Finish Coating and Color Schedule” on Drawing Z-001.2.

3.12 TESTING - GENERAL

A. All piping shall be tested in accordance with these specifications.

B. Functional tests shall consist of leakage tests as specified below. See Section 01 75 17 for additional requirements.

C. Provide all personnel, equipment and materials as required to complete the testing. Equipment and materials might include: pumps, hoses, pressure gauges, nitrogen tanks, leakage measuring device, connections, relief valves, and other necessary apparatus.

D. Testing Gauges:

1. Scale: Register pressure in pounds per square inch gauge (psig).

2. Accuracy: ANSI Grade 3A ( 0.25 percent).

3. Range: From 0 psig to 1.5 times the test pressure. The gauge face shall have a 5 psig increment inscribed.

4. The test gauge assembly shall be equipped with a 1/2" quick connect fitting and isolation valve to allow the Engineer to install a second gauge and a pressure monitoring device.

5. Calibration: The gauge shall be calibrated within 45 days prior to the test and the calibration tag affixed to the gauge. District may test pressure gauges for accuracy.

E. Notification: In addition to the submitted testing schedule, notify the Engineer in writing a minimum of 7 days in advance of filling or testing a section of piping. All tests shall be performed in the presence of the Engineer.

F. All testing shall be completed prior to backfill of any portion of the test segment.


G. Preparation:

1. All valves and other appurtenances shall be installed and tested concurrentlyunless otherwise noted or shown. Remove or suitably isolate appurtenantinstruments or devices that could be damaged by pressure testing.

2. All pipe supports shall be completely installed and approved by the Districtprior to testing.

3. All pipe lining shall be completed, and interior of the pipeline shall bethoroughly cleaned prior to testing.

4. Testing shall not be performed against closed valves except where priorapproval has been granted, in writing, by the Engineer.

H. Filling the Pipeline for Hydrostatic Pressure Testing:

1. All air vents shall be open during the filling of the pipeline with water. After atest section is completely filled, close all air vents.

2. Filling Velocities: 1/4 feet per second, applied over full area of pipe.

3. After filling the pipe, the filling apparatus shall be either disconnected orphysically isolated from the pipeline.

4. Mortar lined pipe sections shall be allowed to stand under pressure for aminimum of 24 hours, to allow the lining to absorb water and permit theescape of air.

5. Examine valves and exposed connections for leaks during this period. Repairall visible or known leaks.

3.13 HYDROSTATIC TEST FOR PRESSURE PIPING

A. Test Pressure: As shown on the MECHANICAL PIPING SCHEDULE, located at the end of this section.

B. Test Procedure: Testing shall be per PFI ES-4 and as follows:

1. Raise the pipeline pressure to the initial test pressure by means of a pumpconnected to the pipe in a manner satisfactory to the Engineer.

2. Test Duration: 30 minutes, minimum, and for such additional time as necessaryto conduct examinations for leakage. Maintain test pressures constantthroughout the duration of the test.

3. While pipe is under pressure, the Contractor shall examine the pipeline forleakage in the presence of the Engineer.

08/19/13 2047 40 20 20 - 36 Mechanical Piping

4. Repair all leaks and retest the pipe. Retest the pipeline as many times asnecessary until all leaks have been corrected.

5. Any damage to the protective lining and coating of the pipe and to the caulkingor jointing material after the testing shall be repaired.

6. Repairs shall be made subject to the approval of the Engineer.

7. Leave pipe full of water unless otherwise directed by the Engineer.

8. Submit the completed “Piping Pressure Test Record” form for approval by theEngineer.

3.14 HYDROSTATIC TEST FOR GRAVITY PIPING

A. Test Preparation: Install inflatable test plug or other device to suitably isolate pipeline segment to be tested. Seal all openings to prevent evaporation.

B. Test Pressure: 10 feet of water at the highest point. Install temporary standpipes as necessary to achieve test pressures.

C. Test Duration: 30 minutes, minimum (unless otherwise noted), and for such additional time as necessary to conduct examinations for leakage.

D. Test Procedure:

1. While test segment is under pressure, the Contractor shall examine the pipingfor leakage in the presence of the Engineer. The test segment shall show nosigns of leakage.

2. Levels in standpipes used for testing shall remain constant throughout theduration of testing. Refilling or topping-off the test segments during the test isnot acceptable.

3. Repair all leaks and retest the pipe. The piping shall be retested as many timesas necessary until all leaks have been corrected.


3.15 PNEUMATIC TESTS

A. General:

1. The Contractor shall recognize the potential hazards associated with pneumatictesting and shall take all necessary precautions to protect personnel.


2. The District reserves the right to perform additional non-destructive tests onany weld at any time at District expense. Contractor shall make allowance inthe schedule for a minimum of ½ day per test for additional District testing.

3. Pneumatic tests shall not be conducted on thermal plastic piping.

B. Testing Media: Oil free air compressor with dryer. Air shall be dried to a maximum dew point of 40 degrees F.

C. Test Pressure: As shown on the MECHANICAL PIPING SCHEDULE and as specified herein.

D. Tests for Saddle Type Branch Connections:

1. Test verifies the integrity of the branch connection welds by pressurizing thespaces between the saddle and the large pipe. Test shall be in accordance withAWWA C206-03 and as specified herein.

2. Test Connections: Two connections on each branch connection saddle; installtesting gauge on one connection and apply test air to the other connection.

3. Test Pressure: 25 psig.

E. Test Procedures:

1. Apply test air and slowly increase to testing pressure.

2. Test Pressures above 25 psig:

a. Conduct a preliminary leak test at 25 psig as a means of detecting majorleaks. Examine the entire pipe segment by means of soap solution.

b. After all leakage has been repaired and retested at the preliminary testpressures, gradually increase the test pressures to no more than ½ themaximum test pressure and re-inspect the test segment for leakage.

c. After all leakage has been repaired and retested at ½ the maximum testpressure, increase the test pressures in 10 percent of maximum testpressure increments until the maximum test pressures are achieved.Monitor the piping for leakage at each pressure increment.

3. The maximum test pressure shall be held continuously for a minimum time of15 minutes and for such additional time as may be necessary to conductexaminations for leakage.

4. Examine the piping for leakage by means of a soap solution applied at all jointsand connections. The piping shall show no soap bubbles or other evidence ofleakage.


5. Repair all leaks and retest the pipe. The pipeline shall be retested as manytimes as necessary until all leaks have been corrected.


3.16 MAGNETIC PARTICLE TEST

A. Perform magnetic particle test per Section 05 05 24, Pipe Welding.


3.17 ACCESSORIES

A. Install ID markers on exposed piping per section 22 05 53.05.

3.18 SUPPLEMENTS

A. The following supplements follow END OF SECTION are a part of this specification:

1. MECHANICAL PIPING SCHEDULE

2. MECHANICAL PIPING PRESSURE TEST RECORD

END OF SECTION


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MECHANICAL PIPING PRESSURE TEST RECORDREFER TO SPEC 40 20 20 – MECHANICAL PIPING SCHEDULE

SPEC NUMBER: TEST NUMBER: DATE:

PROJECT NAME:

TEST INFORMATION SYSTEM CODE & SERVICE DESCRIPTION:

DESCRIPTION OF TEST BOUNDARIES: (Attach Sketch Showing the Boundaries on the related P&ID)

OPERATING PRESSURE (PSIG) OR FT: TEST PRESSURE (PSIG) OR (FT):

TEST METHOD: (CIRCLE ONE)

• HYDROSTATIC PRESSURE • HYDROSTATIC GRAVITY • PNEUMATIC •

PIPE SIZE: PIPE MATERIAL:

TEST REQUIREMENTS REQUIRED TEST PRESSURE: REQUIRED TEST DURATION:

GAUGE PRESSURE CALCULATIONELEVATION DIFFERENCE BETWEEN TEST GAUGE AND HIGH POINT (FT): X 0.434 (CONVERSION FACTOR) = + REQUIRED TEST PRESSURE (PSIG) = EQUALS REQUIRED GAUGE PRESSURE (PSIG) = TEST RESULTSTEST DATE: START TIME: • AM • PM • AMBIENT START TEMP (DEG F):ACTUAL GAUGE PRESSURE @ START (PSIG): FINISH TIME: • AM • PM • AMBIENT FINISH TEMP (DEG F):ACTUAL GAUGE PRESSURE @ FINISH (PSIG): TEST EQUIPMENT (SUBMIT CALIBRATIONS SEPARATELY)TYPE: ID#: LAST CAL. DATE: CAL. DUE: REMARKS: TEST ACCEPTANCECONTRACTOR WITNESS SIGNATURE: DATE:

EBMUD INSPECTOR WITNESS SIGNATURE: DATE:


SECTION 40 42 13.10

PROCESS PIPING THERMAL INSULATION

PART 1 - GENERAL

1.1 DESCRIPTION

A. Section Includes: Insulation for piping and related systems.

B. Related Sections:


2. Section 09 91 00 – Painting.

3. Section 22 05 53.05 – Pipe Identification.

4. Section 22 30 00.01 – Plumbing Fixtures and Equipment.


6. Section 40 20 20 – Mechanical Piping.

1.2 REFERENCES

A. American Society for Testing and Materials (ASTM):

1. A 53 - Specification for Pipe, Steel, Black and Hot-dipped, Zinc-Coated,Welded and Seamless.

2. C 168 - Terminology Relating to Thermal Insulating Materials.

3. C 177 - Test Method for Steady-State Heat Flux Measurements and ThermalTransmission Properties by Means of the Guarded-Hot-Plate Apparatus.

4. C 335 - Test Method for Steady-state Heat Transfer Properties of HorizontalPipe Insulation.

5. C 518 - Test Method for Steady-State Heat Flux Measurements and ThermalTransmission Properties by Means of the Heat Flow Meter Apparatus.

6. C 533 - Specification for Calcium Silicate Block and Pipe Thermal Insulation.

7. C 534 - Specification for Preformed Flexible Elastomeric Cellular ThermalInsulation in Sheet and Tubular Form.

8. C 547 - Specification for Mineral Fiber Pipe Insulation.

08/19/13 2047 40 42 13.10 - 1 Process Piping Thermal Insulation

9. C 552 - Specification for Cellular Glass Thermal Insulation.

10. C 585 - Practice for Inner and Outer Diameters of Rigid Thermal Insulation forNominal Sizes of Pipe and Tubing (NPS System).

11. C 591 - Specification for Unfaced Preformed Rigid Cellular PolyisocyanurateThermal Insulation.

12. C 795 - Specification for Thermal Insulation for Use in Contact with AusteniticStainless Steel.

13. C 929 - Practice for Handling, Transporting, Shipping, Storage, Receiving andApplication of Thermal Insulation Materials for Use in Contact with AusteniticStainless Steel.

14. C 1136 - Specification for Flexible, Low Permeance Vapor Retarders forThermal Insulation.

15. D 2310 - Classification of Machine-Made "Fiberglass" (Glass-Fiber-Reinforced-Thermosetting-Resin) Pipe.

16. E 84 - Test Method for Surface Burning Characteristics of Building Materials.

17. E 96 - Test Methods for Water Vapor Transmission of Materials.

1.3 DEFINITIONS

A. Concealed: Piping above suspended ceilings and within walls, partitions, shafts, or service spaces and spaces not normally exposed to view but not buried.

B. Buried: Piping that is installed below buildings, foundations or finish grade, either in soil or encased in concrete in soil.

C. Exposed: Piping that is not concealed or buried.

D. K Factor: Thermal conductivity determined in accordance with ASTM C 177 or C 518 and expressed in units of [Btu-inch]/[hour-feet2- degrees Fahrenheit].

1.4 SUBMITTALS

A. Product Data:

1. Insulation Properties: Include K factor, thickness, density, operatingtemperature limits, tensile strength, compressive strength, moisture absorption,flame spread and smoke developed in accordance with ASTM E 84 andcorrosivity to stainless steel piping in accordance with ASTM C 795.


2. Jacket Properties: Include covering material, cover thickness, tensile strength,tear strength, permeability per ASTM E 96, flame spread and smoke developedin accordance with ASTM E 84, closure type or devices, and accessories.

B. Manufacturer's Application Instructions: Include assembly and application drawings and detailed instructions.

C. Laboratory Report: Provide certified laboratory report that insulation is not manufactured using chlorinated polymers and does not contain chloride, bromides, sulfates, or fire-retardant materials.

1.5 QUALITY ASSURANCE

A. Regulatory Requirements: In accordance with California Title 24.


A. Store insulation materials under cover and protected from moisture.

B. Handle and store insulation for use on stainless steel in accordance with ASTM C 929.

1.7 PROJECT CONDITIONS

A. As specified in Section 33 12 01.

1.8 SEQUENCING AND SCHEDULING

A. Test piping and heat tracing and obtain acceptance of piping and heat tracing by Engineer prior to applying insulation.

PART 2 - PRODUCTS

2.1 PIPE INSULATION, GENERAL REQUIREMENTS

A. Insulation Thicknesses: Provide insulation thickness in inches in accordance with the following table:


THERMAL PIPING INSULATION THICKNESSES

Service Temperature

Nominal Pipe Diameters

1 inch and less

1.25 to2 inch

2.5 to 4 inch

5 to10 inch

Over10 inch

105 to 200 degrees Fahrenheit 1.5 1.5 1.5 2.0 2.5

40 to 104 degrees Fahrenheit 0.5 1.0 1.0 1.5 2.0

Below 40 degrees Fahrenheit 1.0 1.0 1.5 2.0 2.0

B. Insulation Types: Provide in accordance the drawings and with the Piping Insulation Schedule below.

C. Heat Tracing as required by the specifications and drawings.

2.2 PIPE INSULATION

A. Insulation, Type 1:

1. Insulation Material: Closed cell elastomeric insulation. Tubular form for pipesizes 6-inch and under and sheet form for pipe sizes 8-inch and larger.

2. Temperature Range: Minus 70 degrees Fahrenheit to plus 220 degreesFahrenheit.

3. Thermal conductivity, K Factor at 75 Degrees Fahrenheit: 0.27 or better.

4. Water Vapor Permeability: 0.10 perm-inch or better.

5. ASTM E84 Fire Ratings: 25 or less flame spread index, 50 or less smokedeveloped index.

6. Meets or exceeds: UL181 Mold growth.

7. Maximum Moisture Absorption: 0.2 percent by volume.

8. Joints: Seal with adhesive to form continuous water barrier.

9. Acceptable Products: Armacell AP Armaflex, Nomaco K-flex Flex-Therm, orequal as approved by the Engineer.

B. Insulation, Type 7, Preinsulated Copper Piping:


1. Service Pipe: 20 foot lengths of Type K copper pipe suitable for water atpressures up to 150 pounds per square inch gauge and temperatures to 250degrees Fahrenheit.

2. Insulation: Factory applied polyurethane foam; k factor of 0.14 or less at 70degrees Fahrenheit, average density of 2.0 to 3.0 pounds per cubic foot,suitable for service temperatures up to 250 degrees Fahrenheit.

3. Insulation Cover: Polyvinyl chloride cover pipe; thicknesses in inches to be0.07 for up to 3.5 inch cover pipe diameter, 0.12 for 4 inch to 6 inch and 0.20for 6 inch cover pipe diameter.

4. Field Joints: Slip on bronze coupling with molded high temperature EPDMsealing rings in grooves, set to compensate for expansion and contraction;lubricated with non-toxic lubricant; insulation sealed with compression rubberend seals.

5. Thermal Expansion: Provide design and materials for expansion via slip-onjoint, loops, expansion ells and other fittings as required to accommodateservice pipe thermal expansion, contraction and thrust based on ambient andoperating conditions as specified in the Piping Schedule or as indicated on theDrawings; if not otherwise specified, design for 40 degrees Fahrenheit ambientand 200 degrees Fahrenheit service temperature.

6. Acceptable Products: Thermal Pipe Systems Inc. Copper-Core, Pipe ShieldsInc., or equal as approved by the Engineer.

7. Thrust Blocks and Fittings: Provide design and materials for thrust blocks andanchor fittings at every change in direction.

8. Acceptable Products: Thermal Pipe Systems Inc. Super Temp-Tite, PipeShields Inc., or equal as approved by the Engineer.

2.3 VAPOR BARRIERS

A. Vapor Barrier, Type 1:

1. Material: White kraft paper bound to aluminum foil meeting ASTM C 1136,Type I.

2. Permeability: 0.02 perm or lower.

3. Maximum Flame Spread Rating: 25.

4. Edge Seal: Pressure sensitive tape lap seal.

5. Circumferential Joints: 4 inch wide tape or similar properties or 4 inch wideoverlap with adhesive seal.


6. Acceptable Products: Owens-Corning Fiberglas Corp. all service jackets withDoublesure adhesive lap seal, Schuller Micro-Lok AP-T Plus, or equal asapproved by the Engineer.

2.4 INSULATION JACKETS

A. Jacket, Type 3:

1. Material: Ultraviolet resistant polyvinyl chloride jacketing, 20 mil minimumthickness.

2. System temperature range: 45 deg F to 150 deg F.

3. ASTM E84 Fire Ratings: 25 or less flame spread index, 50 or less smokedeveloped index.

4. Color: White.

5. Overlap: One inch minimum at joints and fittings.

6. Joint Seal: PVC solvent welded or adhesive as recommended by themanufacturer.

7. Fitting Covers: Factory made with full thickness insulation.

8. Acceptable Products: Johns Manville Zeston 2000 PVC, or equal as approvedby the Engineer.

2.5 RELATED MATERIALS

A. Cover Adhesive: Premium adhesive as recommended by the insulation cover supplier for heavy duty service in corrosive, wet environments. Standard duty adhesives are not permitted.

B. Vapor Seal Mastic and Weatherproof Coating:

1. Acceptable Products: Benjamin Foster, No. 30-76, Insul-Coustic, No. I.C.-580,or equal as approved by the Engineer.

PART 3 - EXECUTION

3.1 EXAMINATION

A. Prior to installing insulation, verify that tests of piping systems have been performed at the pressures specified in the Mechanical Piping Schedule in section 40 20 20.

B. Verify that piping surfaces are dry and free of loose scale, rust, dirt, oil, or water prior to applying insulation.


C. Field finish pipe surfaces as specified prior to installation of insulation.

3.2 APPLICATION

A. Apply insulation and cover materials in accordance with manufacturer's written instructions.

B. Apply insulation in smooth, clean manner with tight and finished smooth joints. Do not use torn, cracked, or chipped sections. Fit insulation tightly against surfaces.

C. Apply and test heat tracing where specified or indicated on the drawings beforeinstalling insulation.

D. Apply sealant or cement when previous applications or adhesives and cement have thoroughly dried.

E. Apply insulation to permit expansion or contraction of pipelines without damage to insulation or jacketing.

F. Terminate preformed pipe jackets or covering at sufficient distance from flanges to permit removal of bolts.

G. Overlap flange and flanged fitting insulation on adjacent pipe covering by at least 2 inches.

H. Insulate valves up to packing gland only.

I. Provide continuous insulation through and over pipe supports and provide protection saddles at supports.

J. Extend insulation against insulation end protection shields or covers so that insulation voids do not exist and provide water tight end seals and covers where insulation terminates.

K. Insulate pipeline strainers to permit removal of strainer basket without disturbing insulation on strainer body.

L. Provide continuous pipe insulation and covering through sleeves or openings in walls and floors.

M. Apply premolded pipe insulation with extended legs when used on pipe traced with either tubing or electric cable type.

N. Apply piping identification on jackets as specified in Section 22 05 53.05.


3.3 REPAIR

A. Restore existing insulation and surfaces disturbed or damaged by application of new pipe insulation.

3.4 THERMAL PIPING INSULATION SCHEDULE

THERMAL PIPING INSULATION SCHEDULE

System Code and Service Location(1) InsulationType

Vapor Barrier Type

JacketType

ServiceTemp.

FNotes

TWS - Hot Water C 1 none none 105-200

TWS - Hot Water E 1 none 3 105-200

TWS - Cold Water Outdoor

E

1 none 3 below 40

Notes:1. E or C means exposed or concealed piping, respectively.

END OF SECTION

08/19/132047 40 42 13.10 - 8 Process Piping Thermal Insulation

SECTION 40 80 00

COMMISSIONING OF PROCESS SYSTEMS

PART 1 - GENERAL

1.1 DESCRIPTION

A. Work included:

1. It is the intent of these tests to assure that all Process Control Systems (PCS)equipment supplied is functional and within industry and manufacturestolerances and is installed in accordance with manufacturer’s design andspecifications.

2. The testing and commissioning of the PCS shall be performed by the ProcessControl System Contractor (PCSC).

3. The PCSC shall maintain a written record of the tests and upon completion ofproject, assemble and certify a final test report for review by the District.

4. All testing specified in this Section shall be completed during the perioddefined as “functional testing” in Section 01 75 17. Reference Section 01 75 17for additional details regarding the sequencing of this work.


1. Section 01 45 27 - Shop Inspection

2. Section 01 75 17 - Field Testing and Startup

3. Section 40 90 00 - Instrumentation and Control for Process Systems.

4. Section 40 94 13 - Digital Process Control Computers

5. Section 40 94 33 - Operator Interface Units

6. Section 40 94 43 - Programmable Logic Process Controllers

7. Section 40 95 13 - Process Control Panels and Hardware

8. Section 40 95 20 - Process control Display Devices

9. Section 40 95 33 - Process Control Networks

10. Section 40 95 73 - Process Control Network Cables

08/19/13 2047 40 80 00- 1 Commissioning of Process Systems


A. Experience:

1. The PCSC shall be regularly engaged in the testing of process controlequipment devices, installations, and system integration.

2. The PCSC shall have been engaged in such practices for a minimum of fiveyears.

3. PCSC shall utilize only full-time technicians or engineers who are regularlyemployed by the firm. Electrically unskilled employees are not permitted toperform testing or assistance of any kind. Electricians or linemen may assist,but may not perform testing or inspection services.

1.3 SUBMITTALS

A. The PCSC shall furnish submittals for approval as outlined below:

1. Proposed field functional and acceptance tests

2. Field functional and acceptance test reports

3. Un-witnessed factory test (UFT)

4. UFT report, certifying the UFT was completed satisfactorily

5. Factory demonstration test (FDT)

6. Functional test (FT)

7. Control system functional test (CSFT)

8. List of proposed testing equipment

1.4 SCHEDULING

A. Work shall be coordinated with other systems in accordance with 01 75 17.

B. The PCSC shall notify the Engineer a minimum of two weeks prior to commencement of any testing.


PART 2 - NOT USED

PART 3 - EXECUTION

3.1 GENERAL

A. The PCSC shall perform general equipment inspection and checking procedures recommended by the manufacturer and as specified in other sections of these specifications.

B. Any system, material, or workmanship which is found defective on the basis of acceptance tests shall be reported, corrected and retested all at no additional cost to the District.

3.2 TESTING

A. General:

1. All elements of the PCS hardware shall be tested to demonstrate that the totalsystem satisfies all of the requirements of this specification. The tests areunique to the PCS and the following specification sections:

a. Section 40 94 43 - Programmable Logic Process Controllers.

2. As a minimum, the testing shall include the following:

a. Un-witnessed Factory Test (UFT)

b. Factory Demonstration Tests (FDT)

c. Functional Test (FT)

d. Control System Functional Test (CSFT)

3. The PCSC shall include the tests in the scheduling requirements ofspecification Section 01 75 17 – Field Testing and Startup

4. Each test shall be in the cause and effect format. The person conducting the testshall initiate an input (cause) and, upon the system's producing the correctresult (effect), the specific test requirement will have been satisfied.

5. Except for the Un-witnessed Factory Tests, all tests shall be conducted inaccordance with, and documented on, prior District-approved procedures,forms, and checklists. Each specific test to be performed shall be described anda space provided after it for signoff by the appropriate party after itssatisfactory completion.


6. The District will actively participate in many of the tests. The District reserves the right to test or retest any and all specified functions whether or not explicitly stated in the prior-approved Test Procedures.

7. The District's decision shall be final regarding the acceptability and completeness of all testing.

8. If any of the following witnessed tests or portion of a test fails to the point where it needs to be rescheduled at a later date, additional tests shall be required at the PCSC expense. Included shall be expenses for the Engineer’stravel, accommodations, and sustenance of the same quality used for the original test. Retest expense shall be for a maximum of two persons.

B. Un-witnessed Factory Tests (UFT):

1. Prior to the start of the witnessed Factory Demonstration Test, the panels and panel assemblies shall be inspected and tested at the PCSC factory to ensure that it is fully functional and ready for demonstration testing.

2. All panels and assemblies shall be inspected and tested to verify that they are in conformance with related submittals and these specifications.

C. Factory Demonstration Tests (FDT):

1. At the PCSC factory, the pumping plant control panel 2781-FCS-CP-001 shall be completely assembled, with all internal components functional, PCSC and networking in place so that the control panel can be inspected and the communication and I/O networks tested.

2. PCSC factory demonstration tests shall be witnessed by the District, and the tests shall demonstrate the following:

a. Correctness of wiring from all panel field terminals to all input/output points and to all front of panel components.

b. Proper workmanship and correctness of internal panel and console wiring.

c. Proper operation of operator interface and Ethernet switches.

d. Proper operation and installation of the Ethernet, Modbus, DNP 3.0, and IRIG-B hardware and networks.

3. The PCSC shall allot five eight-hour days for testing and shall have PCSCelectrician or technician available for testing during the duration of the test.

4. At the factory demonstration test, the District shall download software configuration files to the operator interface, PLCs, I/O communication

08/19/132047 40 80 00- 4 Commissioning of Process Systems

modules, and Ethernet switches. These files are for general testing only and will are not the final application files to be used during real system operation.

5. The tests shall demonstrate the specified functions to the satisfaction of theEngineer.

6. All factory test punch list items shall be completed and the Engineer notified inwriting before the panels are released for shipment.

D. Functional Tests (FT):

1. General: Prior to startup, the entire installed PCS shall be certified (inspected,tested, and documented) by the PCSC to ensure the PCS is ready for start up.These inspections and tests shall include the functional test outlined in Section01 75 17 and specific PCS functional tests described in this section.

2. The following PCS functions shall be tested during the FT:

a. Power failure and system restart.

b. Fault detection.

c. Diagnostic functions:

1) On line

2) Off line

3) Error codes

d. Ethernet, DNP 3.0, Modbus, and IRIG-B communications

3. As a minimum, the following PCS items shall be inspected:

a. Wiring

b. Copper and fiber optic network terminations

c. I/O, power supply, I/O rack, fusing, cabling, sub-chassis power supplyloading and calculations

d. Spare installed and non-installed I/O

e. Component layout, future spare allocation

f. Identification, labels:

1) Cables


2) Sub-chassis

3) Power supplies

4) I/O cards

5) Wiring

4. Loop/Component Inspections and Tests: The entire PCS shall be checked forproper installation, calibrated, and adjusted on a loop-by-loop andcomponent-by-component basis from the field device to the PLC I/O terminalsto ensure that it is in conformance with related submittals and thesespecifications.

a. The Loop/Component Inspections and Tests shall be implemented usingDistrict-approved forms and checklists. The testing checklists shall bedeveloped on Microsoft Access and configured to sort and search for allloops that have not been tested, wired, installed, calibrated, etc.

1) Each loop shall have a Loop Status Report to organize and track itsinspection, adjustment, and calibration. These reports shall includethe following information and checklist items with spaces for signoffby the PCSC and District:

a) Project Name

b) Loop Number, assigned by the PCSC

c) Tag Number for each component

d) The following checklist/signoffs for each component:

i) Tag/identification

ii) Installation

iii) Termination-wiring

iv) Termination-tubing

v) Calibration/adjustment

vi) FT complete

e) The following checklist/signoffs for the loop:

i) Panel interface terminations

ii) I/O interface terminations with PCS


iii) I/O signal operation relative to PCS, inputs/outputsoperational: received/sent, processed, adjusted

iv) PCS functions

v) Total loop operational

vi) Space for comments

2) Each active element (except simple hand switches, lights, etc.) andeach PCS I/O module shall have a Component Calibration Sheet.These calibration sheets shall also be developed in Microsoft Accessand configured to sort by loop number and status of calibrationcheck. These sheets shall have the following information, spaces fordata entry, and a space for signoff by the PCSC and the District:

a) Project Name

b) Loop Number (ISA 5.04)

c) Component Tag Number or I/O Module Number

d) Component Code Number

e) Manufacturer

f) Model Number/Serial Number

g) Summary of Functional Requirements, for example:

i) For Indicators and Recorders: Scale and chart ranges

ii) For Transmitters/Converters: Input and output ranges

iii) For Computing Elements: Function

iv) For Controllers: Action (direct/reverse), control modes(PID), configuration diagram, scales

v) For Switching Elements: Unit range, differential(FIXED/ADJUSTABLE), reset (AUTO/MANUAL)

vi) For I/O Modules: Input or output

h) Calibrations; for example:

i) For Analog Devices: Required and actual inputs andoutputs at 0, 10, 50, and 100 percent of span, rising andfalling


ii) For Discrete Devices: Required and actual trip points and reset points

iii) For Controllers: Mode settings (PID)

iv) For analog I/O Modules: Required and actual inputs or outputs of 0, 10, 50, and 100 percent of span, rising and falling

i) Space for comments

j) Space for signoff by the PCSC

b. The PCSC shall maintain the Component Calibration Sheets at the jobsite and make them available to the District at any time.

c. The PCSC shall provide the Loop Status Reports for the District. After a specific test has been completed, the PCSC shall provide a copy of the signed-off test form to the District, and the PCSC shall enter it in the data file.

d. These inspections and tests shall require witnessing by the District.

E. Startup Tests:

1. General: Startup test shall not proceed until the Control System FunctionalTest has been successfully completed. Startup testing shall be in accordance with Section 01 75 17, Field Testing and Startup.

END OF SECTION

08/19/132047 40 80 00- 8 Commissioning of Process Systems

SECTION 40 90 00

INSTRUMENTATION AND CONTROL FOR PROCESS SYSTEMS

PART 1 - GENERAL

1.1 SUMMARY

A. Section Includes:

1. This section covers work by the Process Control System Contractor (PCSC),necessary for engineering, furnishing, installing, calibrating, adjusting, testing,documenting, and starting up the Instrument and Controls for Process Systems(ICPS).

B. Major Constituents: Major constituents of this system shall include all materials, equipment, and work required to implement a complete and operating ICPS and shall include furnishing and installing the following:

1. Primary elements and transmitters, analog display and control elements,discrete primary elements, discrete display and control elements, control panelsand panel mounted devices as shown, and associated ancillary devices.

2. Programmable logic controllers (PLC), and operator interfaces units (OIU).The PCSC shall provide all required software, and the District will perform allPLC and OIU programming.

C. Related work specified elsewhere:

1. Section 01 43 11 – Seismic Requirements

2. Section 01 75 17 – Field Testing and Startup

3. Section 26 05 19 – Low- Voltage Electrical Power Conductors and Cables

4. Division 27 - Communications

5. Section 33 09 11 - Instruments and Recorders

6. Section 40 94 43 - Programmable Logic Process Controllers

1.2 DEFINITIONS

A. Signal Characteristics:

1. Analog signals are 4 to 20 mA dc and shall conform to the compatibilityrequirements of ISA S50.1. Unless otherwise noted, circuits shall be ISAS50.1, Type 2, two-wire. Transmitters shall have a load resistance capabilityconforming to Class L. Transmitters and receivers shall be fully isolated.

08/19/13 Instrument And Control2047 40 90 00 - 1 for Process Systems

Within panels where a common 1 percent dropping resistor is used, analog signals are 2 to 10 Vdc.

2. Discrete signals are two-state logic signals and shall use 24VDC or 120 VACsources as noted.

3. Digital signals are binary coded signals.

1.3 SYSTEM DESCRIPTION

A. Responsibility

1. The PCSC shall be responsible for:

a. Complete systems functionally operational in accordance with the intentof these Contract Documents.

b. Coordinating the details of equipment layouts and construction for allspecification divisions which affect the work covered under Division 40,Process Integration. The majority of process integration coordination isspecified in Division 01, Division 26, Division 27, Division 28, Division33, and Division 40. However, the Contractor is responsible forcoordination with all applicable sections of the contract documents. Thecontract documents are a single integrated document, and as such allDivisions and Sections apply. It is the responsibility of the PCSC toreview all sections to ensure a complete and coordinated project.

c. Furnishing and installing all incidental items not actually shown orspecified, but which are required by good practice to provide completefunctional systems.

2. The PCSC shall provide the following minimum ICPS scope of work:

a. For control panels, components, and ancillaries specified under thisdivision provide the following:

1) Coordinating to ensure that:

a) The proper type, size, and number of signal wires with theirraceways are provided and installed.

b) The proper electrical power circuits with their raceways areprovided and installed.

c) The proper size, type, materials of construction, andconnections of process mechanical piping are provided andinstalled for in-line primary elements.

2) Provide panels, components, and ancillaries.


b. Provide and install field instrumentation.

c. Provide and install PLCs and OIUs.

d. Provide and install control panel fiber optic and copper network cabling.

e. Provide the specified submittals.

f. Provide instructions, details, and advice to, and coordinating with, theContractor to ensure proper installation.

g. Certify correctness of installations.

h. Verify final power and signal connections and labeling (lugging andconnecting).

i. Adjust and calibrate instruments and components.

j. Startup and testing support.

3. The PCSC shall be an instrumentation and control (I&C) system contractor thathas at least 5 years of experience installing similar systems.

4. Electrical Raceways and Wiring: All electrical raceways external to panels,consoles, assemblies, and components provided under Division 40, arespecified, provided, and installed under Division 26, Electrical or Division 33,Utilities. All wiring and cables external to panels, consoles, assemblies, andcomponents provided under Division 40, are specified, provided, installed, andtagged under Division 26, Electrical. All wire terminations are specified to bemade under Division 26, Electrical.

5. The PCSC shall make all final power and signal connections, to all equipmentspecified in Division 40. For all elements provided under Division 40 and allelements interfaced by the I & C system, the PCSC shall verify and certify bywritten notice to the District, correctness of final signal connections andcorrectness of adjustment.

B. Design Requirements

1. Control, status, alarm, and indication functions are shown on the drawings inProcess and Instrumentation Diagram (P & ID) form in accordance with theInstrumentation Society of America (ISA), Standard S5.1, except as noted.These drawings show the functional requirements and general location of eachfunction to be provided.

2. The design of the ICPS is based on the first named manufacturers of theequipment and materials. Should the PCSC select other equipment thatrequires different installation requirements, wiring and conduit, enclosures,accessories, etc., the PCSC shall obtain approval from the Engineer for such


changes to the design in accordance with Article 1.5 SUBMITTALS and shall make all approved changes at no additional cost to the District.

3. Like items of equipment of the ICPS shall be the end products of onemanufacturer and of the same series or family of models in order to achievestandardization for appearance, operation, maintenance, spare parts, andmanufacturer's services. All same or similar functions shall be implemented inthe same or similar manner. For example, control logic, sequence controls,display layouts, etc.

C. Performance Requirements

1. The PCSC shall perform the following functions:

a. Measure and monitor discrete and continuous process and processequipment variables

b. Effectively present the process and process equipment variables to theoperators to allow them to accurately monitor and change the status of theplant's processes

2. The PCSC shall provide all of the functions shown on the contract drawings.Major equipment items are specified; however, all items of materials andequipment, whether indicated or not, that are necessary to effect the requiredloop performance shall be provided.

3. The PCSC shall assign a competent, on-site field representative who shallsupervise the electrical construction work from beginning to completion andfinal acceptance.

4. Skilled workers who have had experience working on similar projects shallperform all labor.

5. The PCSC shall install all equipment and materials in accordance with thedesign and vendor-furnished, District-approved drawings.

6. Any required work to correct improperly fitted installations shall be performedby the PCSC at no cost to the District.

1.4 SUBMITTALS

A. General: In addition to the requirements of Section 01 33 00 Submittals Procedures, the following requirements shall be satisfied for submittals relating to work provided under Division 40:

1. All submittals shall be complete, neat, orderly, indexed with labeled tabdividers. Partial submittals will not be accepted.


2. The number of final copies for each submittal shall be in accordance with Section 01 33 00 unless otherwise noted. Submittals may be broken down into smaller packages with the approval of the Engineer.

a. Design-Related Submittals:

1) Design.

2) Hardware.

3) Application Software.

b. Spares, Expendables, and Test Equipment Lists

3. Before any components are fabricated, and/or integrated into assemblies, or shipped to the site, furnish to the District, and receive for review of full details, shop drawings, catalog cuts, and such other descriptive matter and documentation as may be required to fully describe the equipment and options proposed and to demonstrate its conformity to these specifications. The decision of the District upon the acceptability of any submittal shall be final. Catalog information shall be submitted for all equipment, regardless of whetheror not it is of the same manufacture as that listed in the specifications.

4. All submittals shall be complete, neat, orderly, bound in a three-ring binder and tabbed. Partial submittals will not be accepted. All components shall be referenced by the instrument tag name designations shown. List proposed exceptions and/or deviations to these Contract Documents contained in each submittal.

5. If, in the opinion of the District, a submittal is not clear, it will be returned to the PCSC and it shall be revised and resubmitted.

B. Design-Related Submittals:

1. Design:

a. Submit full details, panel fabrication drawings, panel power distribution drawings, wiring diagrams, panel arrangement drawings, catalog cuts, and such descriptive literature and documentation as may be required to demonstrate conformance to these drawing and specifications. These submittals shall clearly identify specific items and options proposed to be provided. In addition, these submittals shall clearly identify installed spares and other provisions for future work (e.g., reserved panel space; unused components, wiring, terminals, etc.).

b. All design drawings, panel drawings, wiring diagrams, loop diagrams, and interconnection diagrams shall be drafted using the latest version of Autocad or Intergraph's MicroStation. Drawings shall be developed in


accordance with the District's procedures and standards, copies of which are available on request.

c. Legends and Abbreviations Lists: As part of the first Design-RelatedSubmittals for each subsystem, submit a complete definition of symbolsand abbreviations used on this project. For example: engineering units,flowstreams, instruments, structures, and other process items used innameplates, legends, data sheets, and point descriptions. The sameabbreviations shall be used through the design subsystems. Submitupdated versions with subsequent submittals and a final version with theO&M Manuals.

d. Submit complete, detailed panel elementary diagrams of all pre-wiredpanels. Diagrams shall be similar to those typical diagrams shown on thedrawings, but with the addition of all the auxiliary devices such as relays,alarms, fuses, circuit breakers, lights, fans, heaters, etc. Provide panelcontrol diagrams for all discrete control and power circuits. Diagramsshall be ladder type schematic diagrams similar to the typical diagramsshown in the drawings, but shall include all devices requiring electricalconnections. Panel control diagrams shall identify all wire numbers andtypes, terminal numbers, tag numbers, and PLC input/output I/Oidentification (rack and slot) numbers. Control diagrams shall show allcircuits individually; no common diagrams will be allowed. Line numbersand sheet numbers shall reference relay contacts. Where multiple relaysare required, their coils shall be wired parallel. All discrete devices shallbe labeled to define their switching action (close on rising or close onfalling process variable.

e. Submit comprehensive, system-wide interconnecting wiring diagrams thatfollow the format shown on the drawings, showing all component andpanel terminal board identification numbers and external wire numbers inthe same format as shown on the drawings. Wiring tables or wire lists willnot be considered as a suitable substitute for these drawings unlessapproved by the District. These diagrams shall include all intermediateterminations between field elements and panels (e.g., terminal junctionboxes, motor control centers, etc.) and shall document every field wireand cable shown on the cable schedule in the drawings. This requirementcovers all equipment on the project with field wiring installed, not justIPCS equipment. It is the PCSC’s responsibility to obtain shop drawingsand any other necessary documentation from the Contractor forequipment not supplied under the PCSC’s scope of work. These diagramsshall be coordinated with the electrical subcontractor and shall bear astatement that this has been done. Reference the drawings for a typicalinterconnecting wiring diagram showing the format to be used. Thesedrawings shall be provided to the electrical subcontractor for wiringsystem coordination and shall be used to provide wire numbers on thefield wiring that is identical to the panel wire number. When wire


numbers are not shown on the drawings, the PCSC shall contact the District to obtain wire numbers.

f. Submit loop diagrams that shall consist of an individual wiring diagramfor each analog loop showing all devices in the loop, wire and terminalnumbers, the location of the dc power supply, instrument tag numbers anddescriptions, scale ranges, calibration data, and the location of anycommon dropping resistors, fuses, shield grounds, etc. The loop diagramsshall be in the format as shown on the drawings. The loop diagrams shallmeet the minimum requirements of ISA S5.4 plus the followingrequirements:

1) Each loop diagram shall be divided into three areas for identificationof element locations:

a) Panel face

b) Back-of-panel

c) Field (including terminal and/or junction box if used)

2) On each diagram present a tabular summary of:

a) The output capability of the transmitting instruments

3) Loop diagrams shall be on individual 11-inch by 17-inch drawingsand shall include all pertinent information, including calibrationdata, set points, etc.

g. It is not acceptable to combine the information from submittal item 1.5 B1 e (interconnection diagrams) and 1.5 B 1 f (loop diagrams) withoutwritten approval from the Engineer. The PCSC shall submit separate fulland complete submittals for interconnection and loop diagrams in theirbid.

h. Submit power requirement and heat dissipation summary for all controlpanels. Power requirements shall state required voltages, currents, andphases(s). Heat dissipations shall be maximums and shall be given inBtu/hr. Summaries shall be supplemented with calculations. Providecomplete panel power distribution wiring diagrams for each control panel.

i. Panel Construction Drawings: Submit shop drawings and catalog materialfor all control and field panels, instrument racks, and enclosures.Drawings shall be to scale and shall show the location of all panelmounted devices as well as doors, louvers, and sub-panels. Drawingsshall include a panel legend and a bill of materials. The panel legend shalllist and identify all front of panel devices by their assigned tag numbers,all nameplate inscriptions, service legends, and annunciator inscriptions.


The bill of materials shall list all devices mounted within the panel that are not listed in the panel legend, and shall include the tag number, description, manufacturer, and model number for each.

j. Panel Plumbing Diagrams: Diagrams for each panel containing pipingand/or tubing shall be submitted showing pipes/tubes (size and materials);components (type, size, and materials); connections to panel mounteddevices (size and type); and panel interface connections (size and type).

k. Submit drawings showing any modifications or additional details as maybe required to supplement the Contract Documents and adequately definethe installation of the ICPS elements.

l. Submit seismic calculations In accordance with Section 26 05 00Common Work Results for Electrical and Section 01 43 11.

2. Hardware:

a. Bill of Materials: Submit a listing of all the panels, racks, instruments,PLCs, OIUs, and equipment supplied as a part of the ICPS. Allcomponents shall be grouped by component type. Submit the list inelectronic format in a Microsoft Access compatible file and contain, as aminimum, the following:

1) Tag number.

2) Instrument, panel, rack or device, tag number

3) Description

4) Quantity supplied

5) Reference to component data sheet and catalog cut

6) Component type

7) Manufacturer

8) Model number

9) Part number

10) Calibration information

11) Wiring diagram sheet or drawing number

12) Electrical, and process drawing sheet or drawing number


b. Submit catalog information, descriptive literature, wiring diagrams(showing internal wiring and external connections for power and signal),and shop drawings for all recorders, indicators, transmitters, primaryelements, flowmeters, PLCs, I/O modules, OIUs, networking equipmentand appurtenances, and all other components of the ICPS. Also, providecatalog information on all electrical devices furnished under this Division40 (for example: power supplies, relays, surge suppressors, terminalblocks, circuit breakers, heaters, thermostats, lighting, enclosures andelectrical cabinets, fans, louver kits, etc.).

c. Individual data sheet (or specification) listing shall be provided for allcomponents provided under this Division 40. The purpose of these datasheets is to supplement the generalized catalog information provided byciting all specific features for each specific component (e.g.:manufacturer, model number, scale range, set point, materials ofconstruction, special options included, etc.). Each component data sheetshall bear the component name and instrument tag number designationshown in the drawings and Specifications. All data sheets shall use theISA format and shall be done using Microsoft Word, Excel, or Accesswith two copies of the disk files delivered to the District at the end of theproject.

d. Submit catalog information on all electrical devices furnished under thisDivision 40.

e. Submit shop drawings and catalog material for all control panels andenclosures. Provide control panels sized as shown on the drawings.Where control panel dimensions have not been shown, size panels with aminimum of 30 percent spare usable space horizontally and vertically onall internal and external panel surfaces and mounting panels. Drawingsshall be to scale and shall show the location of all panel mounted devices(such as terminal blocks, relays, wire ducts, power supplies, color codingof terminal strips, nameplates, etc.) as well as doors, louvers, andsubpanels. Drawings shall include a panel legend and a bill of materials.The panel legend shall list and identify all front of panel devices by theirassigned tag numbers, all nameplate inscriptions, service legends, andannunciator inscriptions. The bill of materials shall list all devicesmounted within the panel that are not listed in the panel legend, and shallinclude the tag number, description, manufacturer, and model number foreach.

3. O&M Manual Submittals:

a. O&M manuals shall be submitted in accordance with Section 01 33 00and Section 40 01 50 Supplemental Operations and Maintenance ManualRequirements for Process Integration.



A. Qualifications

1. The PCSC shall be a licensed UL508 electrical contractor.

B. Regulatory Requirements

1. Codes and Standards: Unless otherwise specified herein, or shown on thedrawings, work under this specification shall be performed in accordance withthe following codes, standards and publications to the extent indicated by thereferences herein. The date of issue or version shall be the current version attime of bid. Any conflict among these standards shall be brought to theattention of the Engineer for clarification and final ruling.

a. NFPA Standard 70 National Electrical Code

b. IEEE Standard 472 Electrical Surge Protection

c. EIA Standard RS-232-C Interface between data terminal equipment anddata communication equipment employing serial binary data interchange

d. EIA Standard RS-485 Electrical characteristics of balanced voltage digitalinterface circuits

e. NEMA ICS6 Enclosures for Industrial Controls and Systems

f. SAMA PMC-33.1 Electromagnetic Susceptibility of Process ControlInstrumentation

g. IEEE 472 Electrical Surge Protection

h. ISA S5.1 Instrumentation Symbols and Identification

i. ISA S20 Specification Forms for Process Measurement and ControlInstruments, Primary Elements and Control Valves

C. Certifications

1. Underwriters Laboratories Inc.: Unless otherwise specified, electricalequipment and material shall be listed and labeled for the purpose for which itis used by the Underwriters Laboratories Inc. (UL). All control panels providedunder this Division 40 shall have a UL stamp and be constructed by a ULapproved panel fabrication shop.

D. Coordination meetings

1. Coordination meetings shall be held periodically during the course of theproject. The PCSC shall summarize resolutions reached in each coordination


meeting and send a copy to the Engineer. The first meeting shall be scheduled within 90 days after Notice to Proceed is issued to the PCSC. The PCSC shall provide for a minimum of four such meetings.


A. Throughout this contract, the PCSC shall provide protection for materials and equipment against loss or damage and from the effects of weather. Prior to installation, store items in indoors in a dry location and follow all manufacturers' storage instructions. Provide heating in storage areas for items subject to corrosion under damp conditions. Provide covers for panels and other elements that may be exposed to dusty construction environments. Specific storage requirements shall be in accordance with the manufacturer's recommendations of the equipment being provided.

B. Close and latch all panel access doors whenever work is not being done in them and before leaving the site each day.

1.7 SYSTEM STARTUP

A. For certain components or systems provided under this Division 40 but not manufactured by the PCSC, the services of qualified manufacturer's representative shall be provided during installation, startup, and demonstration testing and District training.

1.8 COMMISSIONING

A. Testing shall be performed in accordance with Section 01 75 17 and Section 40 80 00 Commissioning of Process Systems.

PART 2 - PRODUCTS

2.1 GENERAL

A. Seismic design requirements: See Section 01 43 11, Seismic Requirements for seismic requirements, including structural integrity, anchorage, and proof of compliance.

B. All components shall be new and of the best quality, constructed of durable materials, and designed for long life in continuous service with a minimum of maintenance.

C. All mechanisms shall be enclosed in such a manner that they shall be protected against damage from dust, moisture, or striking by external objects.

D. Where shown in the specifications or on the drawings, components shall comply with the referenced codes and standards.

E. All freestanding or floor-mounted equipment shall be front aligned.


2.2 NAMETAGS

A. All components provided under this Division 40, both field and panel mounted, shall be tagged and identified in accordance with Section 26 05 53 Identification for Electrical Systems.

2.3 EQUIPMENT FINISH

A. Provide materials and equipment with manufacturer's standard finish system in accordance with Section 09 91 00, Painting. Provide manufacturer's standard finish color, except where specific color is indicated or specified. If manufacturer has no standard color, finish equipment with light gray color.

2.4 PANELS AND PANEL MOUNTED EQUIPMENT

A. Panels and panel-mounted equipment shall be assembled as far as possible at the PCSC's factory. No work, other than correction of minor defects or minor transit damage, shall be done on the panels at the jobsite.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Install materials and equipment in a workmanlike manner utilizing craftsmen skilled in the particular trade. Provide work that has a neat and finished appearance. Coordinate I&C work with the Engineer and work of other trades to avoid conflicts, errors, delays, and unnecessary interference with operation of the plant during construction. Provide all information necessary to coordinate the control interfaces for the switchgear, medium-voltage control switchboard, VFDs, HVAC, security and all other packaged system controls.

B. Wiring

a. All wiring external to ICPS components and assemblies and all power wiringshall conform to the requirements of Division 26, Electrical.

b. Plastic ducts or ties shall restrain all wiring within ICPS panels andenclosures. Major runs of wiring inside panels shall be installed in plasticducts. Hinge wiring shall be secured at each end so that any bending ortwisting will be around the longitudinal axis of the wire and the bend areashall be protected with a sleeve.

i. Arrange wiring neatly, cut to proper length, and remove surplus wire.All panel wires shall be terminated with ferrules of proper size.Provide abrasion protection for any wire bundles that pass throughholes or across edges of sheet metal.

ii. No more than two wires may be installed on a single screw terminal.Where crimp connections are used, crimper shall be the ratchet type.


iii. For connections to compression clamp type terminals; strip, prepare,and install wires in accordance with the terminal manufacturer'srecommendations. No more than one wire shall be installed in eachcompression screw and yoke.

iv. Wiring shall not be spliced or tapped except at device terminals orterminal blocks. All wiring connections shall be made by terminalblocks, including signal ground shields.

v. 24 Vdc and analog signal circuits shall be terminated on color codedterminal blocks separate from color coded ac circuit terminal blocks.

vi. Separate all analog and other dc circuits at least 6 inches from any acpower and control wiring, except at unavoidable crossover points andat device terminations. Where crossover points exist, they shall crossat right angles.

vii. Conductor tags shall be provided as specified in Section 26 05 19 andSection 26 05 53 and as shown on the drawings.

3.2 CLEANING AND TOUCHUP PAINTING

A. Keep the premises free from accumulation of waste material or rubbish. Upon completion of work, remove materials, scraps, and debris from premises and from interior and exterior of all devices and equipment. Touchup scratches, scrapes, or chips in interior and exterior surfaces of devices and equipment with finishes matching as nearly as possible the type, color, consistency, and type of surface of the original finish. Clean and polish the exterior of all panels and enclosures upon the completion of the FAT.

3.3 SOURCE QUALITY CONTROL

A. Inspection

1. All materials, equipment, and workmanship shall be subject to inspection atany time by the District. Correct any work, materials, or equipment not inaccordance with these Contract Documents or found to be deficient ordefective in a manner satisfactory to the District at no additional cost to theDistrict.

END OF SECTION


SECTION 40 94 13

DIGITAL PROCESS CONTROL COMPUTERS

PART 1 - DESCRIPTION

1.1 GENERAL

A. Work included

1. Furnish two (Qty. 2) control system programming notebook/laptopcomputer(s).

1.2 SUBMITTALS

A. The following items shall be delivered to the District 60 days after Notice to Proceed C/O Dado Hernandez, Senior Electrical Engineer, Instrumentation, Control and Power Engineering Section, Design Division, East Bay Municipal Utility District, 375 11th Street, MS 502, Oakland CA 94607.

1. Control System programming, notebook/laptop computer(s).

1.3 RELATED WORK SPECIFIED ELSEWHERE:

A. Section 01 21 00 - Allowances.

PART 2 - PRODUCTS

2.1 GENERAL

A. The Contractor shall provide an allowance of $1,500 per notebook/laptop to purchase and furnish the number of control system programming notebooks/laptops indicated in Article 1.1. See Section 01 21 00 – Allowances.

2.2 CONTROL SYSTEM PROGRAMMING NOTEBOOK/LAPTOP COMPUTER

A. The notebook(s)/laptop(s) shall meet the specifications of the latest District standard notebook/laptop. Prior to purchasing the notebook(s)/laptop(s), the Contractor shall contact the Engineer and request a copy of the District notebook/laptop specification.

B. Notebook/Laptop Operating System software:

1. The Contractor shall provide the operating system software disk and license foreach notebook/laptop delivered to the District.

PART 3 - NOT USED

END OF SECTION

08/19/13 Digital Process2047 40 94 13-1 Control Computers

SECTION 40 94 33

OPERATOR INTERFACE UNITS

PART 1 - GENERAL

1.1 SUMMARY


1. Furnish and install Operator Interface Units (OIU)

2. Operator Interface Units and related equipment have been specified on a “no orequal” basis in order to match existing District control equipment. Nohardware and software products other than the exact model numbers specifiedwill be acceptable.

3. All software configuration will be provided by the District.



2. Section 40 95 13 - Process Control Panels and Hardware

3. Section 40 96 35 - Process Control Software Programming

1.2 REFERENCES

A. Applicable codes and standards: design, fabricate, assemble, and test equipment so that upon installation and operation in accordance with manufacturer's recommended procedures for this application the equipment will conform with all applicable codes and standards. The date of issue or version shall be the current version at time of bid.

1. NFPA Standard 70 National Electrical Code

2. IEEE Standard 472 Electrical Surge Protection

3. EIA Standard RS-232-C Interface between data terminal equipment and datacommunication equipment employing serial binary data interchange

4. NEMA ICS6 Enclosures for Industrial Controls and Systems

1.3 SUBMITTALS

A. Submittals shall be made in accordance with Section 01 33 00 Submittal Procedures and Section 40 90 00 Instrumentation and Control for Process Systems.

08/19/13 2047 40 94 33 - 1 Operator Interface Units

B. The Contractor shall furnish submittals for approval as outlined below:

1. Product data.

C. The following items shall be delivered to the District 60 days after Notice to Proceed C/O Dado Hernandez, Senior Electrical Engineer, Instrumentation, Control and Power Engineering Section, Design Division, East Bay Municipal Utility District, 375 11th Street, MS 502, Oakland CA 94607.

1. Extra materials specified in this Section.

1.4 DELIVERY, STORAGE AND HANDLING

A. Operator Interface Units shall be fully installed in the control panel prior to shipping to the site from the factory.

1.5 MAINTENANCE

A. Extra materials

1. Provide one spare of every item specified in this Section.

PART 2 - PRODUCTS

2.1 OPERATOR INTERFACE UNIT (OIU)

A. The OIU shall have the following features and characteristics:

1. Processor: 800 MHz, fanless CPU.

2. Memory: 256 MB of Flash memory; 256 MB of DRAM.

3. Connectivity: One Ethernet 10/100 Base-T port, two RS-232 serial ports, 1 USB host port, 1 SD card slot, 1 line out, 1 microphone in.

4. Display: 15 inch active matrix TFT color LCD touch screen display with 1024x768 resolution.

5. Include keypad and touch screen input.

6. Operating Temperature: 0 to 50 degree Celsius with a relative humidity of 10 to 80 percent non-condensing.

7. Aluminum NEMA 4 enclosure.

8. Power: 24 VDC.

9. Acceptable products: Maple Systems, part number HMI5150P, with PLC connecting cable, part number 7446-0137-5, USB configuration cable, part

08/19/132047 40 94 33 - 2 Operator Interface Units

number 7431-0115, and windows-based configuration software, part number EZware. No substitutions.

PART 3 - EXECUTION

3.1 FACTORY QUALITY CONTROL

A. General:

1. Process Control System Supplier service personnel shall perform all factory tests, inspections, and adjustments as specified in section 40 80 00.

END OF SECTION

08/19/132047 40 94 33 - 3 Operator Interface Units

SECTION 40 94 43

PROGRAMMABLE LOGIC PROCESS CONTROLLERS

PART 1 - GENERAL

1.1 SUMMARY


1. Furnish and install Programmable Logic Controllers (PLC) and Remote Terminal Unit (RTU).

2. PLC and related equipment has been specified on a “no or equal” basis in order to match existing District control equipment. No hardware and software products other than the exact model numbers specified will be acceptable.

3. All software configuration will be provided by the District.



2. Section 40 80 00 Commissioning of Process Systems

3. Section 40 90 00 Instrument and Controls for Process Systems

4. Section 40 94 13 Digital Process Control Computers

5. Section 40 95 13 Process Control Panels and Hardware

1.2 REFERENCES

A. Codes and Standards: Unless otherwise specified herein, or shown on the drawings, work under this Specification shall be performed in accordance with the following codes, standards and publications to the extent indicated by the references herein. Any conflict among these standards shall be brought to the attention of the District for clarification and final ruling. The date of issue or version shall be the current version at time of bid.


2. IEEE Standard 472Electrical Surge Protection

3. EIA Standard RS-232-C Interface between data terminal equipment and data communication equipment employing serial binary data interchange

4. EIA Standard RS-422-A.Electrical characteristics of balanced voltage digital interface circuits.

08/19/13 Programmable Logic2047 40 94 43-1 Process Controllers


6. SAMA PMC-33.1 Electromagnetic Susceptibility of Process Control Instrumentation

7. IEEE 519 Recommended Practices and Requirements for Harmonic Control in Electric Power Systems

8. ISA S5.1 Instrumentation Symbols and Identification

9. ISA S20 Specification Forms for Process Measurement and Control Instruments, Primary Elements and Control Valves

1.3 SUBMITTALS

A. Submittals shall be made in accordance with Section 01 33 00 Submittal Procedures and Section 40 90 00 Instrumentation and Control for Process Systems.

B. The Contractor shall furnish submittals for approval as outlined below:

1. Product data.

C. The following items shall be delivered to the District 60 days after Notice to Proceed C/O Dado Hernandez, Senior Electrical Engineer, Instrumentation, Control and Power Engineering Section, Design Division, East Bay Municipal Utility District, 375 11th Street, MS 502, Oakland CA 94607.

1. Extra materials specified in this Section.


A. Programmable Logic Process Control System shall be fully installed in the control panel prior to shipping to the site from the factory.

1.5 MAINTENANCE

A. Extra materials

1. Provide one spare of every item specified in this Section.

PART 2 - PRODUCTS

2.1 PROGRAMMABLE LOGIC CONTROLLER (PLC)

A. Base unit:

1. Acceptable products: Rockwell MicroLogix 1400 Controller, Catalog No. 1766-L32BXBA. No substitutions.


B. Modbus RS-485 communication adapter:

1. Acceptable Product: Rockwell Catalog No. 1763-NC01. No substitutions.

C. Memory module:

1. Acceptable Product: Rockwell Catalog No. 1766-MM1. No substitutions.

D. Expansion I/O module:

1. Analog

a. Acceptable Product: Rockwell Catalog No. 1762-IF4. No substitutions.

E. Programming software:

1. Acceptable Product: Rockwell Catalog No. 9324-RL0300ENE. No substitutions.

F. Interface cables:

1. Channel 0:

a. Acceptable Product: Rockwell Catalog No. 1761-CBL-PM02. No substitutions.

2. Channel 2:

a. Acceptable Product: Rockwell Catalog No. 1747-CP3. No substitutions.

2.2 REMOTE TELEMETRY UNIT (RTU)

A. RTU

1. Acceptable Product: Schneider Electric Control Microsystems SCADAPackCatalog No. TBUP357-1A20-AB20. No substitutions.

B. Interface cables:

1. Serial port COM 2: Schneider Electric Control Microsystems SCADAPack Catalog No. TBUM297218. No substitutions.

2. Serial port COM 3: Schneider Electric Control Microsystems SCADAPack Catalog No. TBUM297217. No substitutions.


PART 3 - EXECUTION


A. Refer to specification Section 40 80 00 for all PLC Factory commissioning and testing requirements.

3.2 INSTALLATION

A. Install equipment specified above as shown on the drawings. Follow all manufacturers’ instructions when installing PLCs, networks, and accessories.

3.3 FIELD QUALITY CONTROL

A. Refer to specification Section 40 80 00 for all PLC field commissioning and testing requirements

END OF SECTION


SECTION 40 95 13

PROCESS CONTROL PANELS AND HARDWARE

PART 1 - GENERAL

1.1 SUMMARY

A. Section includes:

1. Control panel as shown on the drawings and specified herein.


1. Section 01 43 11 – Seismic Requirements

2. Section 01 45 27 – Shop Inspection

3. Section 01 75 17 – Field Testing and Startup

4. Section 26 05 19 – Low-Voltage Electrical Power Conductors and Cables

5. Section 26 05 53 – Identification for Electrical Systems

6. Section 27 11 19 – Communications Terminal Blocks and Patch Panels

7. Section 27 21 23 – Data Communications Switches and Hubs

8. Section 40 80 00 – Commissioning of Process Systems

9. Section 40 94 33 – Operator Interface Units

10. Section 40 94 43 – Programmable Logic Process Controllers

11. Section 40 95 20 – Process Control Display Devices

12. Section 40 95 73 – Process Control Network Cables

1.2 REFERENCES

A. Codes and Standards: Unless otherwise specified herein, or shown on the drawings, work under this specification shall be performed in accordance with the following codes, standards and publications to the extent indicated by the references herein. Any conflict among these standards shall be brought to the attention of the District for clarification and final ruling. The date of issue or version shall be the current version at time of bid.


08/19/132047 40 95 13-1 Panels and Hardware

2. IEEE Standard 472Electrical Surge Protection

3. EIA Standard RS-232-C Interface between data terminal equipment and data communication equipment employing serial binary data interchange

4. EIA Standard RS-422-A Electrical characteristics of balanced voltage digital interface circuits


6. SAMA PMC-33.1 Electromagnetic Susceptibility of Process Control Instrumentation

7. IEEE 519 Recommended Practices and Requirements for Harmonic Control in Electric Power Systems

8. IEEE 472 Electrical Surge Protection

9. ISA S5.1 Instrumentation Symbols and Identification

10. ISA S20 Specification Forms for Process Measurement and Control Instruments, Primary Elements and Control Valves

1.3 SUBMITTALS

A. The Contractor shall furnish submittals for approval as outlined below:

1. Product data.

2. Warranty.

3. Bill of materials.

4. Plan, front, and side view drawing including overall dimensions, weights, and anchoring details.

5. Assembly drawing.

6. All design drawings, panel drawings, wiring diagrams, loop diagrams, and interconnection diagrams shall be drafted using the latest version of Intergraph's MicroStation. Drawings shall be developed in accordance with the District's procedures and standards, copies of which are available on request.

7. Catalog material for all control panels and enclosures. Provide control panels sized as shown on the drawings. Where control panel dimensions have not been shown, size panels with a minimum of 30 percent spare usable space horizontally and vertically on all internal and external panel surfaces and mounting panels. Drawings shall be to scale and shall show the location of all


panel mounted devices (such as terminal blocks, relays, wire ducts, power supplies, color coding of terminal strips, nameplates, etc.) as well as doors, louvers, and subpanels. Drawings shall include a panel legend and a bill of materials. The panel legend shall list and identify all front of panel devices by their assigned tag numbers, all nameplate inscriptions, service legends, and annunciator inscriptions. The bill of materials shall list all devices mounted within the panel that are not listed in the panel legend, and shall include the tag number, description, manufacturer, and model number for each

8. Catalog cuts of all application software being provided

9. Internal schematics (elementary diagrams), wiring diagrams, and point-to-point interconnection diagrams for all components internal and external connections.

10. Detailed panel elementary diagrams of all pre-wired panels. Diagrams shall be similar to those typical diagrams shown on the drawings, but with the addition of all the auxiliary devices such as relays, alarms, fuses, circuit breakers, lights, fans, heaters, etc. Provide panel control diagrams for all discrete control and power circuits. Diagrams shall be ladder type schematic diagrams similar to the typical diagrams shown in the drawings, but shall include all devices requiring electrical connections. Panel control diagrams shall identify all wire numbers and types, terminal numbers, tag numbers, and PLC input/output I/O identification (rack and slot) numbers. Control diagrams shall show all circuits individually; no common diagrams will be allowed. Line numbers and sheet numbers shall reference relay contacts. Where multiple relays are required, their coils shall be wired parallel. All discrete devices shall be labeled to define their switching action (close on rising or close on falling process variable.

11. Shop drawings and catalog material for all control and field panels, instrument racks, and enclosures. Drawings shall be to scale and shall show the location of all panel mounted devices as well as doors, louvers, and sub-panels. Drawings shall include a panel legend and a bill of materials. The panel legend shall list and identify all front of panel devices by their assigned tag numbers, all nameplate inscriptions, service legends, and annunciator inscriptions. The bill of materials shall list all devices mounted within the panel that are not listed in the panel legend, and shall include the tag number, description, manufacturer, and model number for each.

12. Drawings showing any modifications or additional details as may be required to supplement the Contract Documents and adequately define the installation of the PCS elements

13. Interconnecting wiring diagrams that follow the format shown on the drawings, showing all component and panel terminal board identification numbers and external wire numbers in the same format as shown on the drawings. Wiring tables or wire lists will not be considered as a suitable substitute for these


drawings unless approved by the District. These diagrams shall include all intermediate terminations between field elements and panels (e.g., terminal junction boxes, motor control centers, etc.). These diagrams shall be coordinated with the electrical subcontractor and shall bear a statement that thishas been done. Reference the drawings for a typical interconnecting wiring diagram showing the format to be used. These drawings shall be provided to the electrical subcontractor for wiring system coordination and shall be used to provide wire numbers on the field wiring that is identical to the panel wire number. When wire numbers are not shown on the drawings, the Contractor shall contact the District to obtain wire numbers.

14. Loop diagrams that shall consist of an individual wiring diagram for each analog loop showing all devices in the loop, wire and terminal numbers, the location of the dc power supply, instrument tag numbers and descriptions, scale ranges, calibration data, and the location of any common dropping resistors, fuses, shield grounds, etc. The loop diagrams shall be in the format as shown on the drawings. The loop diagrams shall meet the minimum requirements of ISA S5.4 plus the following requirements:

15. Physical drawings showing equipment arrangement and terminal block locations.

16. A listing of all the panels, racks, instruments, PLCs, servers, OIUs, and equipment supplied as a part of the Process Control Panel. All components shall be grouped by component type. The list shall be submitted in electronic format in a Microsoft Access

17. Catalog information, descriptive literature, wiring diagrams (showing internal wiring and external connections for power and signal), and shop drawings for all recorders, indicators, transmitters, primary elements, flowmeters, PLCs, I/O modules, networking equipment and appurtenances, and all other components of the Process Control Panel. Also, provide catalog information on all electrical devices furnished under this Division (for example: power supplies, relays, surge suppressors, terminal blocks, circuit breakers, heaters, thermostats, fans, louver kits, etc.).

18. Equipment seismic qualifications, seismic calculations, and anchorage details as specified in this Section and Section 01 43 11.

19. Thermal load calculations.

20. Complete installation and field assembly instruction manuals.

21. As-built documents and Operation and Maintenance (O&M) manuals.

22. Spare parts list, expendables, and test equipment list.


23. Certified factory test reports.

24. Test procedures including: factory demonstration test, functional test,performance test, and commissioning

25. Test documentation including: factory demonstration test, functional test, performance test, and commissioning


A. Control panels shall be shipped directly to the site from the factory. Before the control panels are shipped, remove all case-mounted instruments from the face of the panels, and repack in their original shipping cartons for shipment to the site with the control panel

B. Throughout this contract, the Contractor shall provide protection for materials and equipment against loss or damage and from the effects of weather. Prior to installation, store items in indoors in a dry location and follow all manufacturers' storage instructions. Provide heating in storage areas for items subject to corrosionunder damp conditions. Provide covers for panels and other elements that may be exposed to dusty construction environments. Specific storage requirements shall be in accordance with the manufacturer's recommendations of the equipment being provided.

1.5 PROJECT CONDITIONS

A. Environmental

1. Ambient temperature range: 0 to +47 degrees Celsius.

2. Ambient humidity range: 5 percent – 95 percent RH non-condensing.

3. Atmosphere: No corrosive gases.

1.6 MAINTENANCE

A. Extra materials:

1. Provide 10 spare fuses for each size and type used in the panel.

2. Provide 5 spare control relays for each size and type used in the panel.

3. Provide 5 spare amber LED indicating lights.

4. Provide 5 spare red LED indicating lights.

5. Provide 5 spare green indicating lights.

6. Provide 10 spare diodes used for PLC and RTU digital outputs.


7. Provide 1 spare DC to DC converter (48 VDC to 24 VDC).

8. PLC Modules: PLC extra materials are specified in Section 40 94 43.

PART 2 - PRODUCTS

2.1 GENERAL

A. Unless otherwise approved by the Engineer, the control panels shall be constructed with external dimensions as shown on the drawings. The panel construction and all interior wiring shall be in strict accordance with the standards listed in part 1.2, Quality Assurance. Instrument arrangement shall be as shown, with minor modifications as may be required for the particular equipment furnished. Modifications shall be subject to the approval of the Engineer

B. The construction of the control panels shall be by a UL listed Industrial Control Panels Fabricator. The panel shall be completely fabricated, instruments installed, wired, and plumbed at the Fabricator’s factory. The same Fabricator shall fabricateall control panels. Unless otherwise indicated, provide all new materials and equipment, free from any defects, and suitable for the space provided. Provide materials and equipment listed by UL wherever standards have been established by that agency.

C. The control panels shall conform to UL listing 508 and bear a UL 508 label stating "suitable for use as an industrial control panel", or built by an UL listed shop.

D. Where two or more units of the same class of materials or equipment are required, provide products of a single manufacturer. Component parts of materials or equipment need not be products of the same manufacturer.

E. Standard products: Unless otherwise indicated, provide material and equipment that is the standard product of manufacturers regularly engaged in the production of such materials and equipment. Provide the manufacturer's latest standard design that conforms to the specifications.

2.2 TYPICAL EQUIPMENT

A. Construction:

1. For cabinets located indoors, cabinet shall be NEMA Type 12, manufactured with 12-gauge steel, with ANSI 61 gray polyester powder paint external finish.Cabinet dimensions are as shown on the design drawings. Include back panelsand side panels as shown on the drawings.

2. For cabinets located outdoors, cabinet shall be NEMA Type 4X, manufactured with 14-gauge Type 316L stainless steel, complete with back panel. Cabinet dimensions are as shown on the design drawings. Include back panels and side panels as shown on the drawings. Cabinets located outdoors shall be supported


by a unistrut metal frame and mounted at the height shown on the design drawings.

3. Seams shall be continuously welded and ground smooth without holes or knockouts.

4. The enclosure shall have a single hinged door. When facing the front of the enclosure, the hinge shall be on the left-hand side and the door latch on the right-hand side.

a. Door shall have heavy-duty continuous hinges, with lockable three-point latch.

b. Door gaskets shall be of oil resistant material and shall be attached with oil-resistant adhesive.

5. Each enclosure shall be provided with a print pocket 12" wide x 12" high x 2" deep provided on door.

6. Acceptable products: For wall mounted enclosures, Hoffman Concept wall-mount enclosure, with Hoffman Concept back panel, or equal as approved by the Engineer.

7. Acceptable products: For pad mounted enclosures, Hoffman free standing type 12 enclosure, with Hoffman side and back panels, or equal as approved by the Engineer.

B. Wiring:

1. Single conductor wiring shall be No. 14 AWG stranded copper with 600 volt Type MTW insulation unless otherwise specified and as follows:

a. 48V DC power supply wiring shall be 600V, Type MTW, No. 12 AWG stranded copper.

b. 24V DC power supply wiring from the power supply output to the individual distribution circuit breakers shall be 600V, Type MTW, No. 12 AWG stranded copper.

2. Reference Section 26 05 19 – Low Voltage Electrical Power Conductors and Cables for general conductor color coding requirements.

3. Wiring to receptacles shall be No. 14 AWG stranded black (line), white (grounded neutral), and green (ground).

4. Instrumentation cables shall be as specified in Section 26 05 19 – Low Voltage Electrical Power Conductors and Cables.


5. No more than 2 wires shall be connected to one terminal.

6. Wires carrying instrument and control D.C. signals shall be physically separated a minimum of 6" from wires carrying A.C. (120 VAC).

7. All wiring shall be neatly routed in wiring ducts and labeled with their assigned wire numbers. Wire labels shall be machine printed, permanent type heat shrinkable polyolefin labels, Brady Permasleeve printable wire markers, or equal as approved by the Engineer.

8. Instruments with grounding terminals shall be grounded to the panel steel. Provide grounding lug for grounding the console to earth ground.

9. Wire termination:

a. Screw type terminals: wires terminated on screw type terminal blocks shall be made of 105 degrees C nylon insulated, crimp-on terminals with fork-type tongue for screw-type terminals, AMP, Inc., or Thomas & Betts Co. Sta-Kon, or equal as approved by the Engineer.

b. Screw clamp terminals: wires terminated on screw clamp terminal blocks such as relays, switches, control units and devices, and power supplies shall be made with plastic insulating color coded collar ferrules. Use twin plastic insulated ferrules for connecting two wires to a single terminal block. Acceptable products: Phoenix Contact Type AI and AI-TWIN, or equal as approved by the Engineer.

Ferrule Color Coding

AC, Power and Controls Gray

DC, Controls and Instruments Red

DC Power Black

Use only manufacturer approved crimping tool designed specifically for the type of ferrule provided.

10. Open-slot-wiring duct sized for the application shall be provided to hold the wires neatly in place. Wiring duct covers shall be hinged. Provide one-inch minimum wire bending radius to prevent wires from being kinked or stressed at the wiring duct junctions. Wiring duct sizes shown on the drawings are minimum sizes; wiring duct fill shall not exceed 50 percent.

11. Whenever there is any discrepancy between wiring drawings and the control schematic, the control schematics shall take precedence.


C. Control units and devices:

1. Terminal blocks: Shall be tubular clamp rated 600 VAC/VDC minimum and as specified on drawings. If fuse terminal blocks are specified, they shall be with built-in puller and with fuse size as shown on drawings. Provide 20percent spare terminals for every terminal strip, space permitting. Terminals shall be clearly and permanently labeled with embossed numbers as shown on drawings.

2. Terminal block jumpers: Where indicated on the drawings, terminal block jumpers shall be pre-made specifically designed for the application. Jumpers designed to screw in on top of terminal blocks are preferred.

3. Provide all necessary accessories, partition plates, separating plates, end cover, group markers, etc., as required for proper installation of the terminal blocks.

4. Standard control terminal blocks:

a. Standard control terminal blocks shall be designed to accept No. 22 to No. 12 AWG wires. Terminal blocks shall be gray colored and rated for 30 amperes, 600 VAC/VDC.

b. Terminal blocks for analog 4-20mA circuits shall be knife-style isolation (circuit disconnect) type.

c. Acceptable products (Allen-Bradley part numbers are listed; or equal as approved by the Engineer ):

1) End Anchor: Allen Bradley 1492-EA35.

2) End Barrier (Single Circuit Terminal Blocks): Allen-Bradley 1492-EB3.

3) End Barrier (Two Circuit Terminal Blocks): Allen-Bradley 1492-EBD3.

4) End Barrier (Grounding Terminal Blocks): Allen-Bradley 1492-EB3-Y.

5) Group Marker: Allen-Bradley 1492-GM35.

6) Fuse Block: Allen-Bradley 1492-H5.

7) Single Circuit Terminal Block: Allen-Bradley 1492-W4.

8) Two Circuit Terminal Block (For digital I/O field wiring interface applications only): Allen-Bradley 1492-WD4.


9) Knife-Style Isolating Terminal Block (For analog 4-20mA or 1-5VDC applications only): Allen-Bradley 1492-WKD3.

10) Grounding Terminal Block: Allen-Bradley 1492-WG4.

11) Side Jumpers: Allen-Bradley 1492-N49.

12) Center Jumpers: Allen-Bradley 1492-CJ6-XX (where XX is the number of poles).

13) Marking Systems (1492-W4 and 1492-WG4 terminal blocks):Allen-Bradley 1492-SM6X12 (snap-in marker cards) or Allen-Bradley 1492-MP-X (individual marker tabs where X is the number, letter, or symbol required).

14) Marking Systems (1492-WD4 terminal blocks):Allen-Bradley 1492-SM6X9 (snap-in marker cards) or Allen-Bradley 1492-MP-X(individual marker tabs where X is the number, letter, or symbol required).

15) Marking Systems (1492-WKD3 terminal blocks):Allen-Bradley 1492-SM5X9 (snap-in marker cards) or Allen-Bradley 1492-MP5-X(individual marker tabs where X is the number, letter, or symbol required).

16) Marking Systems (1492-H5 fuse blocks):Allen-Bradley 1492-SM8X12 (snap-in marker cards).

5. Heavy Duty Terminal Block shall be designed to accept wires up to No. 10 AWG. Terminal blocks shall be gray colored and rated for 30 amperes, 600 VAC/VDC. Acceptable products: Allen Bradley 1492 W6, Phoenix Contact Universal “UK” Terminal Blocks, or equal as approved by the Engineer.

6. Din rail mounted circuit breakers shall be the high density, 2-pole, energy limiting type rated 250VAC or 120VDC, with current ratings as shown on the drawings. Acceptable products: Allen Bradley 1492-GH (250VAC) and 1492-CB Series B (120VDC), or equal as approved by the Engineer.

7. Molded case circuit breakers shall be panel mountable, 2-pole, energy limiting type rated 250VAC or 120VDC, with current ratings as shown on the drawings. The molded case circuit breaker shall have an integral padlockable handle which will allow the circuit breaker to be locked in the off position. The manufacture of the locking device shall be the same manufacture of the molded case circuit breaker. Molded case circuit breaker shall be in accordance with requirements and type specified in Section 26 24 16 Panelboards.


8. Pilot Devices

a. Pushbuttons

1) 30.5 mm diameter, NEMA 4X, momentary contact, extended head, number of contact blocks as specified or as indicated on the drawings, with finger guard terminals

a) Allen-Bradley 800HC-BR1D1 (“Start” pushbutton, 1 NOcontact block, green cap), Allen-Bradley 800HC-BR6D2(“Stop” pushbutton, 1 NC contact block, red cap).

b) Or equal as approved by the Engineer.

b. Combination indicator light/pushbutton

1) 30.5 mm diameter, NEMA 4X, 24VDC, LED lamp, momentary contact, extended head, number of contact blocks and lens color as specified or as indicated on the drawings, with finger guard terminals.

2) Acceptable products:

a) Allen-Bradley 800HC-QRBH24RD1 (“Trouble” pushbutton/light, 1 NO contact block, red lens).


c. Selector switches

1) 30.5 mm diameter, NEMA 4X, maintained contact, standard knob with white insert, finger guard terminals, number of positions and contact development as shown on the drawings.

a) Allen-Bradley 800HC-HR2A (2 position, 1-NO – 1-NC contact configuration).


d. Indicator lights

1) 30.5 mm diameter, NEMA 4X, 24VDC, LED push-to-test lamp, with finger guard terminals, color as specified or as indicated on the drawings.



a) Allen-Bradley 800HC-QRTH24A (amber), 800HC-QRTH24G (green), 800HC-QRTH24R (red).


e. Push-pull operators

1) 2-position push-pull/twist to release, NEMA 4X, maintained contact, with two contact blocks unless otherwise specified or as indicated on the drawings, finger guard terminals.

2) Provide a protective guard to avoid unintentional tripping of E-stop push-pull operators.

a) Allen-Bradley 800HC-FRXT6A5 (“E-Stop”, red cap, 2-NCcontacts with operator in the “out” position).

b) Allen-Bradley 800T-N310 (protective guard for push-pull operator with stainless steel finish).

c) Or equal as approved by the Engineer.

f. Potentiometers

1) 30.5 mm diameter, NEMA 4X, 1k ohm resistance.


a) Allen-Bradley 800H-UR13.


g. Legend plates

1) Provide matching legend plates for the pilot devices specified in this Section. Legend plates shall be white with black letters except for the E-stop legend plate which shall be yellow with black letters.


a) Allen-Bradley 800H-W500 (white/black normal legend plates), Allen-Bradley 800H-W500J (white/black jumbo legend plates), Allen-Bradley 800H-W797A (yellow E-stop legend plates),Allen-Bradley 800H-W080E (custom legend with graduated markings showing a range of 0-20 MGD and title “FLOW SP”).



9. 24V DC Control Relays:

a. DIN rail mounted PLC discrete output interposing relay with 24VDC coil, DPDT contact rating of 10 amperes at 250VAC, and on/off indicatorlight.


a) Control Relay: Phoenix Contact No. 2967620, or equal as approved by the Engineer.

b) Plug-In Jumper: Phoenix Contact No. 2966838 (length as required), or equal as approved by the Engineer.

c) Separation Plate: Phoenix Contact No. 2966841, or equal as approved by the Engineer.

10. 120V AC Control Relays:

a. DIN rail, finger-safe, socket-mounted compact power relay with 120VACcoil, 4PDT contact rating of 10 amperes, and on/off indicator light.


a) Idec RH-4-B-L-AC120V (4PDT, blade terminal, indicator light option, 120VAC coil voltage) with finger-safe DIN rail mount socket SH4B-05C


11. Analog Signal Converters

a. Potentiometer to voltage

1) 0- sensor input from potentiometer, 0-10 VDC output for connection to PLC analog input, 24 VDC powered, with screw connectors.


a) Weidmuller Pro RTD 1000, order number 8679490000.


12. DC to DC Converter (48 VDC to 24 VDC):

a. Switched-mode DC to DC converter, power supply with 24 VDC to 72 VDC input, 12 VDC to 48 VDC output. Output shall be adjustable and regulated 1.0 VDC above or below the standard output voltage. Output


current capability shall be 20 A continuous / 25 A peak at 24VDC nominal output voltage.

b. The power supply shall have an efficiency greater than 85 percent at maximum output, with maximum peak-to-peak voltage ripple of less than 50mV.

c. Power supply shall have the following status signals:

1) Audible and visual indicators for constant current, low input voltage, low output voltage, and overtemperature.

2) Dry contact output fail relay.

d. Provide the following options:

1) Integrally mounted digital volt/ammeter.

2) Conformal coating.

e. Acceptable products: Analytic Systems VTC615 with digital volt/ammeter and conformal coating options, or equal as approved by the Engineer.

13. Electromechanical Timeswitch

a. Shall be a 24 hour dial.

b. Clock motor shall have a rating of 125V, 60 Hz.

c. The switch shall be SPDT and rated for 2 hp.

d. Provide up to 10 ON/OFF operations each day with minimum ON/OFFoperations of 1 hour and maximum ON time of 20 hours.

e. Provide a minimum of 16 hours of spring wound carryover formaintaining preset schedules and time during power failures.

f. Acceptable products

1) Intermatic Inc. Model # T171CR

2) Or equal as approved by the Engineer.


14. Cabinet Door Switch:

a. Cabinet door switch shall be rated for 15 amperes at 120 VAC and 0.5 amperes at 24 VDC, plunger-type door switch, SPST.

b. Acceptable products: Honeywell Microswitch Model 1AC2, or equal as approved by the Engineer.

15. Cabinet Light:

a. Energy efficient fluorescent luminaire with one F15 T8 lamp, white baked enamel housing, white acrylic diffuser, and UL listed for damp locations. The luminaire shall be undercabinet style for surface mounting at the top inside of a control panel.

b. The light shall turn on and off via the integral plunger switch.

c. Acceptable products: Hoffman model ALF16D18R, or equal as approved by the Engineer.

16. Convenience Receptacle:

a. Fully enclosed, DIN-rail mounted, GFI duplex utility receptacle, suitable for either vertical or horizontal mounting, rated 15A at 120VAC.

b. Acceptable products: Phoenix Contact Model EM-DUO-120/15/GFI, or equal as approved by the Engineer.

17. Surge Suppressor:

a. Surge suppressors shall be UL listed and consist of a removable plug and a hardwired base element that accepts wire sizes from No. 20 AWG to No. 2 AWG. Units shall be DIN-rail mounted.

b. Units shall be rated for 120 VAC nominal, 150 VAC maximum and 15kA nominal, 40kA maximum surge current (8/20us).

c. Acceptable products: Phoenix Contact Valvetrab or equal as approved by the Engineer. Valvetrab system part numbers are listed below:

1) Line-Neutral: 120VAC to neutral plug VAL-MS 120 ST Model 2807586; Base element VAL-MS-BE Model 2817741.

2) Neutral-Ground Base and Plug: F-MS 12/FM Model 2817974.


18. Fuses

a. Time delay glass tube construction with nickel plated brass endcaps, 1/4” x 1-1/4” size, for use in Allen-Bradley 1492-H5 fuse blocks.

b. Provide fuse sizes as shown on the drawings.

c. Acceptable products: Bussman MDL or equal as approved by the Engineer.

19. Ground Bar

a. Ground bars shall be UL listed and have suitable number and size of terminals necessary for terminating stranded copper ground wires.

b. Acceptable products:

1) Bus bar base: Phoenix Contact Model No. 0404428.

2) Bus bar terminal blocks: green/yellow color, rated for 76A, Phoenix Contact Model No. 0423027.

3) Copper bus bar: 1/8” x 3/8” tin-plated, Phoenix Contact Model No. 0402174.

4) Or equal as approved by the Engineer.

20. Panel Exhaust Fan and Fan Thermostat

a. Panel exhaust fan shall be UL listed and powered form 120VAC.

b. Shall have integrated cover grill and removable filter.

c. Shall include external thermostat with an adjustable range from 30 DEGF to 140 DEGF.

d. Panel exhaust fan shall be sized according to panel cooling requirements.

e. Acceptable products (Fan): Hoffman Series SF-05 filter fan package, catalog No. SF0516002, or equal as approved by the Engineer.

f. Acceptable products (Thermostat): Hoffman Temperature Control Switch. Hoffman catalog No. ATEMNO, or equal as approved by the Engineer.

21. Panel Heater

a. Panel heater shall be UL listed and powered from 120VAC.

b. Integrated thermostat adjustable from 0 DEGF to 90 DEGF.


c. 200 watt heating capacity.

d. Acceptable products: Hoffman electric heater, catalog No. DAH2001A, or equal as approved by the Engineer.

22. Nameplates

a. Nameplates shall be provided as shown on the drawings, as specified in this Section, and as specified in Section 26 05 53 – Identification for Electrical Systems.

2.3 FIBER OPTIC CABLE PATCH PANELS

A. Refer to Section 27 11 19 Communications Terminal Blocks and Patch Panels for fiber optic cable patch panel requirements.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Install equipment specified above as shown on the drawings. Follow all manufacturers’ instructions when installing PLCs, networks, and accessories.


A. All factory testing shall be in accordance with Sections 01 75 17 Field Testing and Startup and 40 80 00.


A. All field testing shall be in accordance with Sections 01 75 17 and 40 80 00.

END OF SECTION


SECTION 41 22 13.13

OVERHEAD BRIDGE CRANES

PART 1 - GENERAL

1.1 QUANTITY AND LOCATIONS

A. Furnish, install and test one 3-ton electrified overhead, top-running, double girderbridge crane and crane runway rails in accordance with these specifications and the project drawings. Refer to drawing 2117-S-004.

1.2 RELATED WORK SPECIFIED ELSEWHERE

A. Section 01 33 00 – Submittals

B. Section 01 43 11 – Seismic Requirements

C. Section 01 45 27 – Shop Inspection

D. Section 01 75 17 – Field Testing and Startup

E. Section 01 79 00 – Demonstration and Training

F. Section 01 91 13.10 – Asset Identification Tags

G. Section 05 12 00 – Structural Steel Framing

H. Section 05 50 00 – Metal Fabrications

I. Section 09 96 56.05 – Hi Build Epoxy Coatings

J. Section 26 05 00 – Common Works Results for Electrical

K. Section 26 05 83 - Low Voltage Motors

1.3 DESIGN REQUIREMENTS

A. CMAA No. 70, “Specifications for Top-Running Bridge and Gantry Type Multiple Girder Electric, Overhead Traveling Cranes”.

B. ASME B30.2-2005. “Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist)”.

C. Crane Service Class: CMAA No. 70, Class A.

D. Wire Rope Hoist Service Class: ASME HST-4-1999 Class H1 and ASME B30.16; see data sheet.

E. NFPA 70, “National Electric Code”.

08/19/132047 41 22 13.13 -1 Overhead Bridge Cranes

F. NEMA Standards Publication MG-1, “Motors and Geneators”.

G. Building Clearances: Note limits on Drawings and as specified herein.

H. Safety of Operation and Accessibility: OSHA 29 CFR 1910.

1.4 SUBMITTALS

A. Shop Drawings:

1. Make, model, weight, and horsepower of each equipment assembly.

2. Complete catalog information, descriptive literature, materials of construction, and specifications on bridge drive system, end trucks, runway stops, wheels, shafting, drive motor, gears and bearing, steel framing, trolley drive system, hoist motor and assemblies, hook, brakes, starting system, 2-speed contactors,conductors (bus bar, festoon), pendant controls, remote control system, and accessories.

3. Structural design calculations for runway beams and support system and calculations of deflection and loads on building structural components.Include calculations for basis of design of electrification system mounting brackets and concrete anchors. All certified correct by a registered professional engineer with a minimum 5 years experience.

4. Detailed Shop Drawings of crane runways, brackets, hangers, and their attachments to the building concrete structure including electrification systemmounting details. Shop Drawings shall include weld symbols for all welds in accordance with AWS A2.4.

5. Power and control wiring diagrams, including terminals and numbers.

6. Motor nameplate data in accordance with NEMA MG 1 and include any motor modifications.

7. Factory finish system.

8. Provide amperage and voltage drop calculations as the basis of sizing the electrification system.

B. Quality Control Submittals:

1. Factory Functional Test Report.

2. Special shipping, storage and protection, and handling instructions.

3. Manufacturer's printed installation instructions.

4. Manufacturer’s field training lesson plans (see section 01 79 00)


5. Manufacturer's Certificate of Proper Installation.

6. Field Functional Test Reports and Logs.

7. Certified Crane Inspector’s Report.

8. Suggested spare parts list to maintain the equipment in service for a period of 1year. Include a list of special tools required for checking, testing, parts replacement, and maintenance with current price information.

9. List special tools, materials, and supplies furnished with equipment for use prior to and during startup and for future maintenance.

10. Operation and maintenance manuals.

1.5 ENVIRONMENTAL REQUIREMENTS

A. Temperature: Maximum 110 degrees F; minimum 33 degrees F.

B. Humidity: 0 to 90 percent.

C. Seismic Zone: Refer to section 01 43 11.

1.6 SPARE PARTS

A. Manufacturer’s recommended spare parts for first year of service.

B. Manufacturer’s special tools.

C. Manufacturer to submit recommended parts list during Submittal approval process.

1.7 QUALITY CONTROL

A. The District intends to perform shop inspection of the crane. See Section 01 45 27 for Shop Inspection Requirements. The intent is all welds will be inspected by District, prior to application of any coatings. Mechanical and Electrical components will also be inspected.

B. The crane will be fully inspected by District after installation and before acceptance.

C. The crane shall be inspected by, tested and certified by an independent 3rd party crane certification agency, in accordance with OSHA regulations.

1.8 MANUFACTURER’S FIELD SERVICES:

A. Manufacturer’s Representative: the Contractor shall furnish the services of a factory trained field representative designated by the equipment/system manufacturer, who shall be present at the project site to provide the services listed below. The manufacturer’s representative shall have superior knowledge of all aspects of the equipment/system being furnished in this section. The manufacturer through their


field representative shall advise the Contractor and the Engineer of the proper procedures for each of the services listed.

B. Training Services: the manufacturer’s representative shall be present at the site and classroom designated by the Engineer, for the minimum number of days listed below.

Minimum Total Time

(Person-Days*)

Manufacturer's Service

1 Installation assistance and certification.

1/2 Field testing and startup (see Section 01 75 17 for additional requirements)

Training of District personnel: See Section 01 79 00 for additional requirements.

* The person-days shown are total days for each service listed. One person-day is equivalent to 8 hours. The person-days shown are the minimum days required for each service, and travel time to and from the site and/or classroom is not included.

PART 2 - PRODUCTS

2.1 GENERAL

A. The crane shall comply with OSHA 29 CFR 1910. The crane shall comply with all “shall statements” and “should statements” of the applicable design codes listed in the design requirements. The crane shall be an electrically powered top running bridge, double girder, electrically powered top running trolley and electric wire rope hoist type.

B. Crane manufacturer shall furnish a coordinated operating system for two speed or VFD drives with pendant control system.

C. Rated Capacities and Speeds: The rated capacities (100 percent) in tons of 2,000 pounds and corresponding rated speeds (plus or minus 10 percent), shall be as follows:


Device - Capacity: Rated Speeds (all motors two speed):

(Note: see 2.9.C for motor controls )

Bridge - 3 Tons 45 / 15 feet per minute (2 speed or VFD)

Trolley- 3 Tons 33 / 11 feet per minute (2 speed or VFD)

Hoist - 3 Tons 15 / 5 feet per minute (2 speed or VFD)

2.2 SUPPLEMENTS

A. See supplements to this section for additional requirements.

2.3 RUNWAY

A. Provide runway rails, crane stops, conductors, brackets, and attachment hardware. Structural components shall be in accordance with Section 05 12 00, Structural SteelFraming.

B. The runway rails shall be A.S.C.E. Rail, 40# / yard.

C. Crane bridge runway electrification shall be enclosed safety type copper busbar system, located on east side of building. See the Drawings.

2.4 BRIDGE

A. Provide girders from structural shapes proportioned to resist vertical, lateral, and torsional forces.

B. Construct bridge end trucks in accordance with CMAA No. 70. End trucks shall have rail sweeps and impact-absorbing bumpers.

C. End trucks shall be of four or eight wheel design.

D. Install runway end stops and bridge bumpers designed for the collision forces specified in ASME B30.17. The center of the end stop strike area shall match the bridge bumper height and shall not engage the wheels. The end stops shall be located so that the crane will provide the required hook coverage while maintaining required clearances from obstacles.

E. Layout of components on the bridge, such as motor controls, motors, reduction gears, electrification system shall be such as to allow access for maintenance.

F. Clearances, wheel loads, and tolerances shall be in accordance with CMAA No. 70.Wheels shall be rolled or forged steel with heat treated treads and flanges with a minimum tread hardness of 350 Brinell. The wheel axles shall be fabricated from alloy steel and machined to receive inner bearing races. Use rotating axles and wheels mounted by press fit and keys.


G. The crane bridge shall have a dual motor drive, one motor for each runway’s wheel drive assembly. Each motor shall be coupled to the truck wheels via a gearbox mounted on the truck frame.

H. Drive gears shall be helical, spur, or herringbone-type fabricated from rolled or cast steel with machine cut teeth.

I. Bearings shall be double row, spherical ball, combination radial thrust type, either pre-lubricated and sealed or fitted for pressure lubrication. Pressure lubrication fittings shall be accessible from a man-lift and clearly labeled with “grease here.”

J. Brakes shall be designed in accordance with ASME B30.17 with the additional requirement of a minimum brake torque rating of 100 percent of the full motor torque adjustable down to 50 percent. The additional requirement shall not dictate design if braking torque is less than specified per the above standard. Each drive shall be equipped with an electro-mechanical disc brake with a self return to ON manual release mechanism so that the bridge may be released by hand.

2.5 OVERHEAD BRIDGE CRANE TROLLEY

A. The frame shall be fabricated from structural steel shapes and designed to control deflection of the trolley assembly while transmitting the carrying load to the bridge rails.

B. Trolley shall top running, four wheel, single motor drive type with trolley brake. Crane trolley electrification shall be festoon type.

C. The drive shall consist of a trolley drive shaft, driven by a two speed electric motor through a gear reduction unit.

D. Wheels shall be rolled or forged steel within a minimum tread hardness of 250 Brinell. Wheel axles shall be alloy steel and machined to receive inner bearing races. Use rotating axles and wheels mounted by press fit and keys.

E. Drive gears shall be helical, spur, or herringbone-type fabricated from rolled or cast steel with machine cut teeth.

F. Bearings shall be combination radial and thrust type, double row, angular contact ball bearings or single-row tapered roller bearings. Bearings shall be prelubricated and sealed, or fitted for pressure lubrication. Pressure lubrication fittings shall be accessible from a manlift and clearly labeled with “grease here.”

G. Brakes shall be designed in accordance with ASME B30.17 with the additional requirement of a minimum brake torque rating of 100 percent of the full motor torque adjustable down to 50 percent. The additional requirement shall not dictate design if braking torque is less than specified per above standards. The drive shall be equipped with an electro-mechanical disc brake with a self return to ON manual release mechanism so that the trolley may be released by hand.


H. Install trolley stops and bumpers designed for the collision forces specified in B30.17. The center of the stop strike area shall match the trolley bumper height and shall not engage the wheels. The stops shall be located so that the trolley will provide the required hook coverage while maintaining required clearances from obstacles. Note trolley stops specific to avoid HVAC ducts. See drawings.

2.6 HOIST

A. The hoist shall consist of a rope drum driven through gear reductions, load blocks, hook, hoisting rope, sheaves, hoist braking and overload limit device. The wire rope drum shall be designed so all wire rope is wound in a single layer and not less than two turns of wire rope remain on the drum when the hook is at its lowest position. Hoist shall be two part single reeving.

B. Hoist shall comply with ASME B30.16 and ASTM HST 4M Class H1 Standards.

C. Rope drum and surrounding members shall be constructed to minimize abrasion, crushing or jamming of hoist rope. The load blocks shall be steel, enclosed type. The hoisting rope shall be extra flexible, improved plow steel made especially for hoist service. The drum shall be fabricated from steel with machined helical grooves.

D. The hook shall be constructed with sufficient ductility to allow noticeable deformation before hook failure. The hook shall be equipped with a safety latch, be free to rotate 360 degrees with rated load and positively held in place with locknuts,collars or other devices.

E. The load block shall be constructed so the hook can be easily removed for inspection purposes.

F. Brakes shall be designed in accordance with ASME HST-4-1999 and B30.16 with the additional requirement of a minimum brake torque rating of 250 percent of the full motor torque. The additional requirement shall not dictate design if braking torque is less than specified per above standards. The brakes shall consist of oneelectro-mechanical disc type with manual lever self return to “ON” release mechanism, and one mechanical load brake so the load may be released by hand and allowed to gradually descend by gravity. Conical brakes are not allowed.

G. The hoist system shall include an overload limit device as described in CMMA specification No. 70, Article 4.3.

H. Hoist gear box cover shall include oil level sight gauge.

I. Hoist shall include an upper travel cutoff limit switch.


2.7 ELECTRICAL

A. Provide electrical equipment including motors, motor controllers, pendant control, control systems, wire, and conduit. The bridge conductors may be removed for shipment.

B. Electrical shall be in accordance with NFPA 70, NEC Article 610 and CMAA Specification 70. All wires shall be numbered or tagged at connection points.

C. The crane shall be designed to operate on 480 V, three-phase, 60-hertz alternating current power in an indoor environment. The bridge crane control panel shall include a fused main disconnect switch or main circuit breaker and shall have provisions to be locked in the Open position.

D. Electrification System (Powerails).

1. The bridge crane power rail shall be a preassembled, enclosed 4 conductorsystem. The power rail system shall be located where shown on the Drawings,at both pumping plant sites.

2. Provide all necessary components of the power rail system including but not limited to; power feed devices, collectors, end caps/covers, brackets, anchor clamps and rails.

3. The power rail assembly shall be firmly anchored to the concrete wall via brackets at spacing recommended by the manufacture.

4. The collector bars shall be sized based on the total load of the bridge crane system and per the requirements of NEC, Section 610.

5. Power rails shall be as manufactured by Vahle, US Safety Trolley or Approved Equal.

E. Bus-way shall include door bus-way to permit insertion or removal of trolleys.

F. Bridge and trolley conductor voltage drops from runway supply taps shall permit the crane motors to operate within voltage tolerances of plus or minus 10 percent, when building supply voltage is at plus or minus 5 percent of design voltage.

G. The festooned flat cable conductors for trolley electrification shall be a flexible cable, carried by heavy-duty roller with permanently lubricated roller bearings on a monorail support system that will dispense and retrieve the flexible cable without twisting or tangling with 20 percent spare conductor in each cable assembly.

H. Grounding: External in accordance with NFPA 70, NEC Article 250. Bridge and trolley frames shall be grounded with a separate conductor and not by means of the wheels and tracks.


I. The crane system supplier shall coordinate the power requirements with the power source (distribution panelboard feeder breaker) and make sure the feeder breaker is coordinated with the main circuit breaker or switch in the bridge crane control panel.

2.8 MOTORS

A. The bridge and trolley drive motors shall be crane duty rated, and shall be two speedoperated with speeds noted in 2.9.C, with rated load.

B. The hoist motor shall be hoist duty rated, and shall be two speed operated with speeds noted in 2.9.C, with rated load.

C. All motors shall be totally enclosed non-ventilated (TENV). The motor insulation shall be Class F or better rated and shall be thermally protected with sensors embedded in the motor windings.

D. All motors shall have a 30-minute (minimum) duty rating.

E. The motors shall run smoothly, without torque pulsation at the lowest speed, and shall be energized at a frequency not exceeding 60 hertz at rated speed.

2.9 CONTROLS

A. Each crane function shall have a separate and independent drive unit with a motor circuit protection device.

B. All enclosures shall be rated NEMA 12 or greater.

C. The controllers for the bridge, trolley drive and hoist mechanisms shall each be two-speed type, NEMA rated contactors and be integral with the unit. Each motor/ gear drive shall be sized to provide sufficient starting torque for initiation of motion of the crane mechanism from standstill with rated load on the hook.

1. The bridge drive shall provide two speeds or variable speed capable of; 45 feet per minute and 15 feet per minute.

2. The trolley drive shall provide two speeds or variable speed capable of; 33 feet per minute and 11 feet minute.

3. The hoist drive shall provide two speeds or variable speed capable of; 15 feet per minute and 5 feet per minute.

D. Dynamic braking shall be provided for each drive. The hoist, trolley, and bridge electro-mechanical brakes shall set after the associated controller decelerates the motor to a controlled stop. All electro-mechanical brakes shall set upon loss of power.


E. The main disconnect switch or main circuit breaker at the control panel shall disconnect all power to the crane system. Under voltage protection shall disconnect the crane upon loss of utility power and shall not allow reconnection until an operator resets the system via a keyed reset switch located in the crane control panel.

F. Two upper limit switches shall be provided for the hoist. The primary limit switch shall allow the operator to lower the hook only. Lowering the hook past the primary limit switch shall cause the primary limit switch to automatically reset. The secondary limit switch shall open all input power conductors to the motor drive and set the brake. Power shall be returned via a keyed, spring returned to normal bypass switch located on the pendent. Once power is restored operation shall be limited to the down direction until the primary limit switch is reset. The primary limit switch shall be set at the maximum practical hook height. The secondary switch shall be set at a distance equal to the primary limit switch height plus the distance required for the hook to coast to a stop from full rated speed with no load.

G. The pendant shall have spring loaded cable reel to accommodate the various elevations required for operation, i.e. from mezzanine (upper) level and main pump floor (lower level). Length of pendant shall be such that bottom of pendant is threefeet above lower level floor when fully extended.

H. A lower limit switch shall be provided for the hoist. The lower limit switch shall be set at the lowest practical hook height and when reached shall allow the operator to raise the hook only. Raising the hook past the lower limit switch shall cause the lower limit switch to automatically reset.

I. Provide pendant control station suspended from the bridge on its own independent trolley. Offset pendant a minimum of 6-foot distance from hook.

1. Heavy-duty, oil tight, pushbutton enclosure supported with chain or wire ropewith suitable strain relief grip.

2. Control cable attached to support chain or wire rope at not more than 6-foot intervals.

3. Momentary contact type pushbuttons for the following functions:

a. Main contactor ON/OFF.

b. Bridge NORTH and SOUTH with two speed control.

c. Trolley EAST and WEST with two speed control.

d. Main hoist UP and DOWN with two-speed control.

2.10 ACCESSORIES

A. The trolley and bridge shall include directional markings indicating building north, south, east, and west. The markings do not have to coincide with actual north but shall suit final building orientation. The markings shall match the labels on the pendent and remote control.


2.11 FACTORY FINISHING

A. Prepare and prime coat in accordance with Section 09 91 00, Painting and Protective Coatings, System No. 6. Crane color shall be Federal Safety Yellow.

B. Crane capacity shall be stenciled in letters in black not less 12” in height on each side of bridge, close to center of the bridge.

2.12 SOURCE QUALITY CONTROL

A. Factory Inspections: Supplier shall inspect equipment for required construction, electrical connection, and intended function.

B. District Inspection: See Section 01 45 27 for General Shop Inspection requirements and procedures. District shall be notified upon completion of all welding, prior to application of coatings. The District intends to inspect the crane after completion of welding. Coatings shall not be applied without written approval from District. The District shall also inspect Mechanical and Electrical Components of the crane including comparison of equipment provided against all submittals.

C. Factory Tests and Adjustments:

1. No-load run test all equipment furnished.

2. Hoist full rated load test in fabricator’s shop to ensure proper operation of trolley and bridge drives.

2.13 ACCEPTABLE MANUFACTURERS/ PRODUCTS, MOTORIZED OVERHEAD CRANES

A. Craneworks Inc., San Leandro, CA.

B. Heco Pacific Manufacturing Inc., Union City, CA.

C. Craneworks Inc., San Leandro, CA.

D. Allied Crane Co., Pittsburg, CA.

E. ACCO / Wright Hoists & Crane Components.

F. Yale Hoists

G. Or equal as approved by the Engineer.

2.14 ASSET IDENTIFICATION TAGS

A. Provide tags per Section 01 91 13.10, Asset Identification Tags.


PART 3 - EXECUTION

3.1 INSTALLATION

A. Install and test in accordance with manufacturer's printed instructions, the project drawings and these specifications.

B. Provide lubricants.

C. Install electrical powerail system per the manufactures recommendations and NEC Section 610. Refer to the electrical and mechanical drawings for location of the powerail.

3.2 FIELD FINISHING

A. Field Finish: Coating of all cranes shall be the system and color as designated on the “Finish, Coating and Color Schedule” on drawing 2117-Z-001.2.

B. Touch-up equipment as specified in Section 09 91 00, Painting and Protective Coatings, System No. 6.


A. See Section 01 75 12, Field Testing and Start Up.

B. Functional Test: Conduct on each crane.

1. Alignment: Test complete assemblies for proper alignment and connection, and quiet operation.

C. Performance Test:

1. Conduct on each Pump Room overhead bridge crane, and beam/trolley in Camanche Lime Storage Room.

2. Load tests in compliance with OSHA, ANSI B30.11, and ANSI B30.16.

D. Inspection by Certified Crane Inspector. Provide letter of certification to the District.

3.4 SUPPLEMENTS

A. The supplements listed below, following “END OF SECTION,” are a part of this Specification. Also, see the project drawings.

1. Crane Data Sheet.

2. Induction Motor Data Sheets (three).

END OF SECTION


X

X

X

X X XX

X X X

X3 X3 X3

X3 X3 X3

X X

X

Accessories:X Service Platform

Central Lubrication SystemX OSHA Operating and Safety Devices XX Manlift Accessible Grease Fittings

Notes:1. See Project drawing 2117-S-004 for clearances, lift distances, and details.2. "*" Indicates items to be completed by the Manufacturer and submitted for approval.3. Either type, two-speed or VFD, is acceptable. VFD speeed range shall encompass the 2 speeds shown.

Remote Controls:

Frequency Modulated (FM)

H3 (standard) H5 (severe)

H2 (light)H4 (heavy)

Bridge Drive System (CMAA): A1 A4

A2 A5

Model No.:

Rev/Date/By:

*

*

F (continuous)

2 SPEED START/STOP3 TONS

PENDANT

BRIDGE

Double Girder

A (standyby)C (moderate)E (severe)

B (light)D (heavy)F (continuous)

Top RunningLow Profile

Type:

Hand Operated, Chain

A (standard)C (moderate)E (severe)

H1 (standby)

*

Method of Control: Location of Control:

Required Not Required Equipment Capacity:

Single Girder

CRANE DATA SHEET

OVERHEAD TRAVELING CRANE

GENERAL REQUIREMENTS


EAST BAY MUNICIPAL UTILITY DISTRICTALMOND PUMPING PLANT - SERVICE CRANE

2781-BAS-CRN-021

Project: Owner: Service: Equip. Tag Number:

Outdoors Indoors Equipment Location:

Not Required

Manufacturer:

Type:

Factory Testing:

Field Testing:

15/5 (2 speed) Constant Speed(s) with Soft-Start

B (light)

Motor hp:Electric Conductors:

Service Class (ANSI):

Type:

Constant Speed(s) with Soft-Start33/11 (2 speed) Speed(s) (fpm):

Variable Speed Drive (range above)

Hook Travel: See dwg1*

Electric Operated, Wire Rope

Constant Speed(s) with Soft-Start

HOIST

Required, Functional & Performance

*

TROLLEY

Underhung

Motor hp: *

Festoon

Infrared, line-of-sight

D (heavy)

Service Class (ANSI): Service Class (ANSI):

Underhung

Speed(s) (fpm): Speed(s) (fpm):45/15 (2 speed)

- Overload limit device - Upper travel cutoff limit switch - Pendant control with cable reel

Top Running

A3 A6

Motor hp: Main Runway Electric Conductors:

Bus Bar

Variable Speed Drive (range above)

Additional requirements:

1Number of Units:

2047 Overhead Bridge Cranes41 22 13.13

Power Supply:

Motor Spec: 26 05 83

08/19/13

Voltage (VAC): 460 VACPhase: 3

60Frequency (Hz):

Variable Speed Drive (range above) Hand Operated Hand Operated

SPECIAL REQUIREMENTS

Bus Bar Cable Reel

Festoon Other

Wired

Project:Owner:Equipment Name:Equipment Tag Number(s):

Type: Squirrel-cage induction meeting requirements of NEMA MG 1Bridge drive includes two drive motors, one for each runway.

Manufacturer: For multiple units of the same type of equipment, furnish motors and accessories of a singlemanufacturerMotor shall have 30 minute (minimum) duty rating and NEMA Class "F" insulation.Hazardous Location: Furnish motors for hazardous (classified) locations that conform to UL 674 andhave an applied UL listing mark

Motor Horsepower: Guaranteed Minimum Efficiency at Full Load: percentVoltage: Guaranteed Minimum Power Factor at Full Load: percentPhase: Service Factor (@ rated max. amb. Temp.): 1.0Frequency: Enclosure Type:Synchronous Speed: rpm Mounting Type: Horizontal Vertical

Two speed motor Vertical Shaft: Solid Hollow

/ rpmConstant Horsepower Two speed motor 45 fpm, 14 fpm bridge speedVariable TorqueConstant Torque Thermal Protection:

Winding: One Two Space Heater: volts, single phaseOversize main terminal (conduit) box for motors

Current Draw____*____ Amps , Max Terminal for connection of equipment grounding wire in eachterminal box

Additional Motor Requirements: Section 26 05 00, Common Work Results for Electical

Special Features:

08/19/132047 41 22 13.13 Overhead Bridge Cranes

INDUCTION MOTOR DATA SHEET

1.15

Almond Pumping PlantEast Bay Municipal Utility District

Overhead Crane, Bridge Motors

* Max *460 VAC

360 HZ

*

*

TENV

* *

Note 2: See separate data sheets for trolley drive motor and hoist motor.

Type *120

Note 1: * indicates items to be completed by crane manufacturer.

X

X

X

XX

X

XX


Type: Squirrel-cage induction meeting requirements of NEMA MG 1



Two Speed Vertical Shaft: Solid Hollow

/ rpmConstant Horsepower Two speed motor, 33 fpm, 11 fpm trolley speedVariable TorqueConstant Torque Thermal Protection:


Current Draw ___*____ Amps, Max Terminal for connection of equipment grounding wire in eachterminal box

Additional Motor Requirements: Section 26 05 00, Common Work Results for Electrical

Special Features:


Note 2: See separate data sheets for bridge drive motor and hoist motor.

Type *120


* *

60 HZ*

460 VAC3

*

TENV


1.15

Folsom South Canal Pumping PlantsEast Bay Municipal Utility District

Overhead Crane Trolley Motor

* Max *

X

X

X

XX

X

XX


Type: Squirrel-cage induction meeting requirements of NEMA MG 1



Two Speed Motor Vertical Shaft: Solid Hollow

/ rpmConstant Horsepower Two speed motor, 15 fpm, 5 fpmVariable TorqueConstant Torque Thermal Protection:


Current Draw: ______*___ Amps, Max Terminal for connection of equipment grounding wire in eachterminal box

Additional Motor Requirements: See Section 26 05 00 for Common Work Results for Electrical

Special Features:


Note 2: See separate motor data sheets for bridge and trolley drive motors.

Type *120


* *

60 HZ*

460 VAC3

*

TENV


1.15

Folsom South Canal Pumping PlantsEast Bay Municipal Utility District

Overhead Crane Hoist Motor

* Max *

X

X

X

XX

X

XX

X

SECTION 43 21 13.15

IN-LINE CENTRIFUGAL PUMPS

PART 1 - GENERAL

1.1 DESCRIPTION

A. Work included: Furnish and install, complete, constant speed, horizontal, end suction centrifugal pump for standby service water service, frame mounted, with motor and drip rim base, fully assembled, as specified herein and as shown on the drawings.

B. Related work specified elsewhere:


3. Section 01 79 00 – Demonstration and Training.

4. Section 01 91 13.10 –Asset Identification Tags.

5. Section 03 62 00 – Non-Shrink Grouting.

6. Section 05 05 26 – Flange Bolting.

7. Section 09 96 56.05 – High-Build Epoxy Coatings.

8. Section 26 05 00 – Common Work Results for Electrical.

9. Section 26 05 83 – Low Voltage Motors.


11. Section 40 20 20 – Mechanical Piping

1.2 SUBMITTALS

A. Submit the following prior to fabrication:

1. Dimensional drawings, catalog information, and materials of construction forpumps, motors, mechanical seal, base, and all appurtenances.

2. Pump performance characteristic curves plotting the following parametersversus flow rate in gallons per minute:

a. Head in feet.

b. Brake horsepower.

08/19/13 2047 43 21 13.15 - 1 In-Line Centrifugal Pumps

c. Net Positive Suction Head required (NPSHr).

d. Efficiency

3. Impeller diameter.

4. Motor nameplate data.

5. Maximum solid particle size.

B. Submit the following prior to shipment:

1. Factory performance test curves.

2. Hydrotest certificate.

3. Final O&M manuals.

C. Submit the following prior to contract completion:

1. Manufacturer's Certificate of Proper Installation.

2. Certified Field Test Reports.

1.3 OPERATION AND MAINTENANCE (O&M) MANUALS

A. In addition to the requirements of Section 01 33 00, Submittal Procedures, provide the following:

1. All performance data.

2. Provide a copy of the equipment manufacturer's warranties.

3. Provide section dividers for the Field Test Reports and Manufacturer’sCertificate of Proper Installation (to be inserted by the District when available).

1.4 MANUFACTURER'S FIELD SERVICES

A. Manufacturer's representative shall be present at the site or classroom designated by the Engineer, for the minimum person-days listed, travel time excluded:

Person-Days Manufacturer's Service

1/2 Installation assistance, inspection, and certification.

1 Field testing and startup (see Section 01 75 17 for additional requirements)


PART 2 - PRODUCTS

2.1 PUMP SUMMARY TABLE

Table A

In-line Centrifugal Pump Summary

Equipment ID Description Rated Flow1

(GPM)

Rated TDH1

(FT)

Motor HP

2781-CWS-PMP-121 Cooling Water Pump 100 50 3

Notes1/ The design point is a preliminary estimate and is dependent on the cooling water requirements of the approved TEWAC motor manufacturer. The final design point will be provided after approval of the TEWAC motor submittal.

2.2 SERVICE CONDITIONS

A. Service: Cooling water to TEWAC motor.

B. Liquid Pumped: Clear, cold, treated water (potable water).

C. Largest Solids Passing: 1/4”.

D. Pumping Temperature: 70 degrees F.

E. Specific Gravity, at 70 degrees F: 1.0.

2.3 PERFORMANCE REQUIREMENTS

A. Guaranteed Performance:

1. Rated Capacity: Per Table A.

B. Minimum Pump Efficiency at Rated Capacity: 57 percent.

C. Brake Horsepower shall not exceed 110 percent of the nominal rating of motor at any point of curve above 67 percent of the design head.

D. Speed: 3600 rpm maximum.

2.4 PUMP CONSTRUCTION

A. Pump Type: Vertical, 180 degree in-line, single or multi-stage, floor mounted with stand or base flange. Assembled with motor and coupling and coupling guard.


B. Casing: Cast iron ASTM A48 or ductile iron.

C. Impeller: Enclosed type, bronze or stainless steel. Secure to shaft by key and self-locking nut, or capscrew and lock washer. Impeller shall be dynamically and hydraulically balanced. Impeller shall be factory trimmed to match the rated conditions.

D. Casing Wear Rings: Replaceable bronze or brass.

E. Shaft: Solid stainless steel, 300 series or 400 series, or carbon steel with bronze or stainless steel sleeve

F. Connections: Sizes 2” and smaller NPT threads or ASME flanges. Sizes 2.5” and larger shall be ASME flanges.

G. Mechanical Seal:

1. Provide a cartridge type single mechanical seal, non-pusher, single coil spring,with silicone carbide versus ceramic seal faces, John Crane Type 1100, orequal as approved by the Engineer.

I. Bearings: Outboard end, steel ball or roller thrust bearing; inboard end, steel ball or roller radial bearing. Grease lubricated. Rating Life B-10 (20,000 hours minimum) as defined by AFBMA Standards.

J. Bearing Lubrication: Lifetime sealed, greased.

K. Baseplate: Cast iron or heavy fabricated steel, with drip rim and grout holes. Factory mount pump and driver.

L. Coupling: Falk or Fast spring-grid or gear type flexible spacer coupling, with OSHA coupling guard.

2.5 ACCEPTABLE PRODUCTS

A. Grundfos CR Series

B. Goulds Pumps 3996 Series

C. Sulzer-Paco VL Series

D. Or equal as approved by the Engineer.

2.6 MOTOR

A. Motor shall be sized such that 110% of nominal HP is not exceeded at any point of pump curve.

B. See Section 26 05 83 for additional motor requirements.


2.7 FACTORY FINISH

A. Pump, motor, frame and baseplate shall be coated in accordance with Section09 96 56.05, High-build Epoxy Coatings.

2.8 FACTORY TESTS

A. Motor: in accordance with Section 26 05 83.

B. Pump: Performance test with minimum of five points. Curves shall be prepared for flow vs. head, flow vs brake horsepower, flow vs efficiency. Curves shall be submitted for approval prior to shipment.

C. Hydrotest: Casing shall be hydrotested at 200 psig minimum. Hydrotest certificate shall be submitted with performance test curves prior to shipment.

D. Vibration: Vibration levels measured at the pump and at the motor bearing frame/supports shall not exceed a velocity of 0.08 in/sec peak to peak at any discrete frequency.

2.9 PUMP NAMEPLATE

A. Nameplate shall include name of manufacturer, model, size, serial number, capacity (gpm), TDH and direction of rotation.

B. Nameplate shall be brass or stainless steel. Nameplate shall be secured to pump at easily viewed location with stainless steel screws.

2.10 SPARE PARTS AND SPECIAL TOOLS

A. Furnish the following securely packaged and labeled with component name and manufacturer’s model and part number:

Equipment Quantities

complete set gaskets and 0-ring seals 1

shaft sleeve (if applicable) 1

complete set shaft keys. 1

complete mechanical seal 1

case wear ring 1

impeller wear ring (if applicable) 1

one complete set of any special tools required to dismantle pump

1


2.11 ASSET IDENTIFICATION TAGS

A. Provide tags per Section 01 91 13.10, Asset Identification Tags.

PART 3 - EXECUTION

3.1 INSTALLATION

A. Care during storage, installation, and lubrication shall be in strict accordance with the manufacturer's recommendations.

B. Install in accordance with manufacturer’s instructions, Section 33 12 01, and the project drawings. Mount pumps and drivers on concrete bases as shown on the drawings.

C. Adjust pump assemblies such that the driving units are properly aligned and plumb.

D. Anchor bolts shall be stainless steel, and shall be sized in accordance with the pump manufacturer’s drawings.

E. After the pump and driver have been set in position, aligned, and shimmed to the proper elevation, grout the space between the bottom of the baseplate and the concrete foundation with a poured, non-shrinking epoxy grout as specified in Section 03 62 00.

F. All strain from attached piping shall be eliminated from the pumps, and any evidence of pump or driver misalignment, noisy operation, or other signs of improper setting shall be corrected by the Contractor.

G. Field Finish: Coating of all pumps and motors shall be the system and color as designated on the “Finish, Coating and Color Schedule” on Drawing Z-001.2.

3.2 FIELD TESTING

A. Functional Test: The Contractor, assisted by the pump manufacturer’s field representative, shall conduct functional tests in accordance with Section 01 75 17.

B. Performance Test: The Contractor shall perform performance tests as noted below and Section 01 75 17.

1. Measure and record pump shut-off head. Value shall be within 5 percent ofperformance curve.

2. Measure and record motor draw amps. Value shall be within 5 percent ofestimated, based on measured head and calculated current based on BHP vs.head curve and measured voltage.


3. Vibration: Measure using District’s vibrometer. Peak to peak velocity shall notexceed value given in paragraph 2.8.D Factory Tests, of this Section. Recorddata in test record.

4. Insert results into the O&M manual.

END OF SECTION


A P P E N D I X A

FORMS AND SCHEDULES

ITEM TITLE PAGE

1. Submittal Log................................................................................................. A-1

2. Value Engineering Change Proposal ............................................................. A-3

3. Contract Change Order Form......................................................................... A-5

4. Release Form ................................................................................................. A-7

5. California Department of Industrial Relations "Public Works PayrollReporting Form" (Sample) ............................................................................ A-9

6. Escrow Agreements for Security Deposits in Lieu of Retention ................... A-11

7. Subcontractor Payment Report (Form P-047) .............................................. A-15

8. Concrete Data Sheet ....................................................................................... A-17

9. Motor Data Sheet ........................................................................................... A-19

10. Field Functional Test Data Form ................................................................... A-21

11. Asset List Sample Template and Instructions ................................................ A-23

12. Manufacturer’s Certificate of Proper Installation .......................................... A-25

13. Safe Work Permit .......................................................................................... A-27

14. O&M Manual Review Checklist ................................................................... A-39

15. Maintenance Summary Form ......................................................................... A-33

16. Pump Control Panel Acceptance Test Procedure Samples A & B ................ A-35

17. Flushing and Chlorination Checklist ............................................................. A-37

18. Flushing Sample Taps .................................................................................... A-39

19. Training Evaluation Form .............................................................................. A-41

20. Vertical Turbine Pumps Performance Test Forms ........................................ A-43

21. Photo Confidentiality Agreement .................................................................. A-45

08/19/13 Appendix A 2047 Forms and Schedules

Shop Dwg.

Catalog

Sample

Certificate

Test Data

Manual

Other

SU

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ITTA

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ITE

MN

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A-1

VALUE ENGINEERING CHANGE PROPOSAL

SPECIFICATION NO. _________ DATE

PROJECT TITLE

CONTRACTOR __________________________________________________ VECP NO.

1. DESCRIPTION OF EXISTING CONTRACT REQUIREMENT:

2. DESCRIPTION OF PROPOSED CHANGE:

3. DISCUSSION OF DIFFERENCES BETWEEN EXISTING REQUIREMENTS ANDPROPOSED CHANGE: Give advantages and disadvantages of each, justify any changes tofunction or characteristics, and give effect of the change on performance of the item.

0A - 3 Appendix A

4. ANALYSIS: Identify and describe each part of the existing requirement which must be changedto implement this VECP, and recommend how to make such change.

5. LIFE-CYCLE COST EFFECTS: State the estimated effect of the proposed change on cost ofoperating and maintenance throughout the life-cycle of the item.

6. DEADLINE DATE FOR IMPLEMENTATION OF THIS VECP: State the latest time foracceptance of this VECP by the District in order to obtain maximum cost reduction duringremainder of contract.

7. TIME OF COMPLETION: State the effect on contract time of completion if this VECP isaccepted.

8. COST ANALYSIS:

a. Cost of performing the work in accordancewith existing requirement. Attach detailedbreakdown $__________

b. Cost of performing the work in accordancewith proposed VECP. Attach detailed breakdown. $__________

c. Gross Savings to the Contractor. $__________

d. Implementation Costs.

(1) Contractors Development andImplementation Cost. Attach detailed breakdown. $__________

(2) Estimated District Cost. $__________

9. ESTIMATED VALUE ENGINEERING SAVINGS $__________

10. ESTIMATED NET SAVINGS TO CONTRACTOR $__________(c. minus d. above)

0A - 4 Appendix A

CONTRACT CHANGE ORDEREFFECTIVE ONLY WHEN SIGNED BY THE DISTRICT

Project: CHANGEORDER NO.

DATEREQUESTED

BY

SPECIFICATION NO. PURCHASE ORDER NO.

Subject:

1. DESCRIPTION OF WORK TO BE DONE OR CHANGE TO BE MADE

2. PAYMENT TO BE MADE OR CREDIT TO BE TAKEN:

a. Fixed Price Adjustment ( agreed price or specified reimbursement)b. Force Account Work

3. TIME EXTENSION(S) GRANTED:

a. Indicate what time extension applies to.

CHANGE ORDER TOINCLUDE THESEAPPLICABLE ITEMS:

Page 5PARAGON Project Management System

CHANGE AMOUNT

INCREASED

DECREASED

NOTE:For the valuable consideration itemized in this change order, the contractor releases EBMUD from all claims whether known or not, for delay, disruption, acceleration,re-sequencing, overhead,or other impacts, arising out ofor resulting from the work or change described in this change order.

CONTRACTOR

ACCEPTED BY

CONTRACTOR'S SIGNATURE PRINTED NAME TITLE DATE

You are hereby directed to make the above described changes fromthe plans and specifications, or to do the above described work notincluded in the plans and specifications on your contract.

RECOMMENDED BY TITLE DATE

TITLE DATEAPPROVED BY

CHGO02-02-EBMUD Change Order Form

A – 7 Appendix A

R E L E A S E

FOR AND IN CONSIDERATION of the sum of _________________ ______ ($ ), (Contractor Name)

on behalf of itself and its subcontractors, material suppliers, officers, directors, shareholders, employees, representatives, partners, subsidiaries, affiliates, agents, insurers, sureties, successors and assigns (collectively "Contractor") hereby releases and discharges the East Bay Municipal Utility District and its officers, directors, employees, representatives, agents, insurers, sureties, successors and assigns from any and all claims, demands, actions, causes of action and obligations, including but not limited to all claims for direct expense, indirect expense and schedule impact of whatever nature, known or unknown, existing, claimed to exist or which can hereafter ever arise out of or result out of or result from or in connection with any event, transaction or occurrence which has occurred with respect to the ________ _ project under Specification _______ from the beginning of time to and including the date of execution of this release, excepting only the following claims:

[List claims or state “none”]

To the extent of the release provided for herein, Contractor waives any and all rights or benefits it may have under the terms of Section 1542 of the California Civil Code which provides as follows:

"A general release does not extend to claims which the creditor does not know or suspect to exist in his or her favor at the time of executing the release, which if known by him or her must have materially affected his or her settlement with the debtor."

IN WITNESS WHEREOF, said Contractor has executed this Release this ____ day of ______, 20___.

(SEAL) Contractor

By:

Title:

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(Paper Size then 8-1/2 x 11 inches)

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with the authority to act for and on behalf of (Position in business)

, certify under penalty of perjury (Name of business and/or contractor)

that the records or copies thereof submitted and consisting of (Description, number of pages)

are the originals or true, full, and correct copies of the originals which depict the payroll record(s)

of the actual disbursements by way of cash, check, or whatever form to the individual or

individuals named.

Date: Signature:

A public entity may require a stricter and/or more extensive form of certification.

A-10

ESCROW AGREEMENT FOR SECURITY DEPOSITS IN LIEU OF RETENTION

A - 11 Appendix A

This Escrow Agreement is made and entered into by and between East Bay Municipal Utility District whose address is 375 Eleventh Street, Oakland, California 94607 hereinafter called “Owner,” whose address is

hereinafter called “Contractor” and whose address is hereinafter called “Escrow Agent.”

For the consideration hereinafter set forth, the Owner, Contractor, and Escrow Agent agree as follows:

(1) Pursuant to Section 22300 of the Public Contract Code of the State of California, the Contractor has the option to deposit securities with the Escrow Agent as a substitute for retention earnings required to be withheld by the Owner pursuant to the construction contract entered into between the Owner and Contractor for in the amount of dated (hereinafter referred to as the “Contract”). Alternatively, on written request of the Contractor, the Owner shall make payments of the retention earnings directly to the Escrow Agent. When the Contractor deposits the securities as a substitute for the contract earnings, the Escrow Agent shall notify the Owner within ten days of the deposit. The market value of the securities at the time of the substitution shall be at least equal to the cash amount then required to be withheld as retention under the terms of the contract between the Owner and Contractor. Securities shall be held in the name of the East Bay Municipal Utility District, and shall designate the Contractor as the beneficial owner.

(2) The Owner shall make progress payments to the Contractor for those funds which otherwise would be withheld from progress payments pursuant to the contract provision, provided that the Escrow Agent holds securities in the form and amount specified above.

(3) When the Owner makes payment of retentions earned directly to the Escrow Agent, the Escrow Agent shall hold them for the benefit of the Contractor until the time that the escrow created under this contract is terminated. The Contractor may direct the investment of the payments into securities. All terms and conditions of this agreement and the rights and responsibilities of the parties shall be equally applicable and binding when the Owner pays the Escrow Agent directly.

(4) The Contractor shall be responsible for paying all fees for the expenses incurred by Escrow Agent in administering the Escrow Account and all expenses of the Owner. These expenses and payment terms shall be determined by the Owner, Contractor and Escrow Agent.

2047


A - 12 Appendix A

(5) The interest earned on the securities or the money market accounts held in escrow and all interest earned on that interest shall be for the sole account of Contractor and shall be subject to withdrawal by Contractor at any time and from time to time without notice to the Owner.

(6) The Contractor shall have the right to withdraw all or any part of the principal in the Escrow Account only by written notice to the Escrow Agent accompanied by written authorization from the Owner to the Escrow Agent that the Owner consents to the withdrawal of the amount sought to be withdrawn by Contractor.

(7) The Owner shall have a right to draw upon the securities in the event of default by the Contractor. Upon seven days’ written notice to the Escrow Agent from the Owner of the default, the Escrow Agent shall immediately convert the securities to cash and shall distribute the cash as instructed by the Owner.

(8) Upon receipt of written notification from the Owner certifying that the contract is final and complete, and that the Contractor has complied with all requirements and procedures applicable to the contract, the Escrow Agent shall release to the Contractor all securities and interest on deposit less escrow fees and charges of the escrow account. The escrow shall be closed immediately upon disbursements of all monies and securities on deposit and payments of fees and charges.

(9) The Escrow Agent shall rely on the written notifications from the Owner and the Contractor pursuant to Sections (5) to (8), inclusive, of this agreement and the Owner and Contractor shall hold the Escrow Agent harmless from the Escrow Agent’s release, and disbursement of the securities and interest as set forth above.

(10) The names of the persons who are authorized to give written notice or to receive written notice on behalf of the Owner and on behalf of the Contractor in connection with the foregoing, and exemplars of their respective signatures are as follows:

2047


A - 13 Appendix A

On behalf of the OWNER: On behalf of the CONTRACTOR:

East Bay Municipal Utility District ____________________________________ Company Name

Treasury Manager Title Title

Wanda Hendrix-Talley Name Name

Signature Signature

Address: Address:

375 Eleventh StreetOakland, CA 94607

Telephone: (510) 287-0231 Telephone: ( ) Fax: (510) 298-0293 Fax: ( )

On behalf of the ESCROW AGENT:

____________________________________ Company Name

Title

Name

Signature

Address:

Telephone: ( ) Fax: ( )

2047


A - 14 Appendix A

At the time the escrow account is opened, the OWNER and CONTRACTOR shall deliver to the ESCROW AGENT a fully executed counterpart of this Agreement. IN WITNESS THEREOF, the parties have executed this Agreement by their proper officers on the date first set forth above.

OWNER: CONTRACTOR:

East Bay Municipal Utility District Company Name

Wanda Hendrix-Talley ____________________________________ Name Name

Treasury Manager Title Title

Signature Signature

2047

(SAMPLE)

(NOT TO SCALE)

Project Name:Construction Spec. No.:

Agreement Date:Notice To Proceed Date:

WMWW

EMMEMW

PRIME:

SUB:

$0 $0 $0 $0#DIV/0! #DIV/0! #DIV/0! #DIV/0!

$0 $0 $0 $0#DIV/0! #DIV/0! #DIV/0! #DIV/0!

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WMWW

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$0 $0 $0 $0#DIV/0! #DIV/0! #DIV/0! #DIV/0!

Date Signature $0 $0 $0 $0#DIV/0! #DIV/0! #DIV/0! #DIV/0!

$0 $0 $0 $0#DIV/0! #DIV/0! #DIV/0! #DIV/0!

Print Name

*If revised $ amount is less than original $ amount by 10% or more, include statement justifying reason(s) for

Ethnic Minority (EM)EM%

TOTAL PAYMENTS & TOTAL PERCENTAGESWhite Men (WM)

The undersigned verifies that the information provided is corrected.

WM %White Women (WW)

WW%

ORIGINAL DOLLAR AMOUNT

Submission Date:

SUBCONTRACTOR PAYMENT REPORT (P-047)This information reference data from the Contract Equity Program Summary (P-035

Project Completion Date:Original Contract Amount:Revised Contract Amount:

REVISED DOLLAR

AMOUNT*

TOTAL PAYMENTS TO

DATE

PROJECTED TOTAL PAYMENTSCITY STATE ZIP CODE WORK PERFORMEDBUSINESS

PHONE NO.BUSINESS NAME VENDOR ID NUMBER CONTACT NAME STREET ADDRESS

PAGE 1 SUB-TOTALS & PERCENTAGESWhite Men (WM)

WM %White Women (WW)

Ethnic Minority (EM)EM%

WW%

PROJECTED TOTAL PAYMENTSWORK PERFORMED

ORIGINAL DOLLAR AMOUNT

REVISED DOLLAR

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TOTAL PAYMENTS TO

DATEBUSINESS NAME VENDOR ID

NUMBER CONTACT NAME STREET ADDRESS CITY STATE ZIP CODE BUSINESS PHONE NO.

A - 15

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A - 16

PROJECT PROJECT NO.

LOCATION DATE

STATION ELEVATION

WEATHER

CONTRACTOR SOURCE PLANT

LOAD NO. TAG NO. AD-MIX

SPECIFIED STRENGTH MIX NUMBER

SPECIMEN REPORTSPEC.

NO.TEST AGE

TIME MADE

CONC. TEMP.

AIR TEMP. SLUMP WORKABILITY

COMMENTS

CONSTRUCTION INSPECTOR

Concrete Data Sheet

08/19/132047 A - 17 Appendix A

MOTOR DATA SHEET – ALMOND PUMPING PLANT

Motor No.: Service:Horsepower *

SpeedSynchronous RPM *

Full Load RPM *Voltage *Phase *Frequency *Full Load Amps *Locked Rotor Amps *Secondary Amps *

Volts *Field Amps *

Volts *Power Factor (%) Efficiency (%) Full Load * *

75% Load * *50% Load * *

Torque Design (A B C D) *Starting Torque (% of Full Load) *Full Load Torque *Breakdown Torque (% of Full Load) *Load WK2 *Time Duty (Cont. or Time Rated) *

Insulation Class *Temperature Rise Over 40oC Ambient *Thermal Protection Required (Winding) *Enclosure *Frame Number *Horizontal or Vertical *Space Heaters Watts/Volts *Bearings *Rotation (Viewed From Shaft End) *Drive Connection *Slide Rails (Yes or No) *Power Factor Correction Capacitor (KVAR) *Service Factor *Starting Time @ Rated Voltage, Cold (40oC) Hot @ Rated Temp. Rise * *Allowable Time @ Locked Rotor at Rated Voltage, Cold (40oC) *Allowable Time @ Locked Rotor at Rated Voltage, Hot @ Temp. Rise *Shaft Diameter Length * *

Keyway *Motor Weight *Manufacturer *Outline Drawing *Serial Number *Surge Protection *Stator Shift *Approved By: Date Spec. No.Mechanical-Electrical- Item No.

IssueTo

Prelim.Issue

Apprv. Issue

Revisions

1 2 3 4 5Eng'gPurch.VendorField

Notes: N/A - NOT APPLICABLE * - DATA FURNISHED BY CONTRACTOR

07/02/12 A-19 Appendix A2047 Motor Data Sheet

FIEL

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FAC

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con

trac

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Add

the

appr

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cilit

y na

me.

If p

roje

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ntai

ls m

ore

than

one

faci

lity,

add

bot

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ith th

e pr

imar

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cilit

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first

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CIL

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BR

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the

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abo

ve F

acili

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ame

(s).

Item

s 1

thou

gh 5

bel

ow a

re re

quire

d on

the

prel

imin

ary

Ass

et L

ist S

prea

dshe

et.

NO

TE: A

fter r

evie

win

g th

e lis

t of e

xam

ples

on

the

Ass

et L

ist S

prea

dshe

et, t

hey

may

be

rem

oved

.En

tere

d by

con

trac

tor.

Com

pone

nts

of th

e eq

uipm

ent t

ag n

umbe

r are

gen

erat

ed fr

om fi

elds

1a

to 1

e be

low

. A

ll eq

uipm

ent t

ag n

umbe

rs s

hall

be in

com

plia

nce

with

the

follo

win

g dr

awin

gs: 9

492-

G-0

01.2

, -0

02,

-006

, and

-00

7. A

ll ne

w ta

gs d

evel

oped

by

the

Con

tract

or m

ust b

e re

view

ed b

y th

e D

istri

ct fo

r com

plia

nce

with

Eng

inee

ring

Sta

ndar

d P

ract

ice

(ES

P) 1

30.0

.

Ente

red

by c

ontr

acto

r.A

two-

to-fo

ur d

igit

num

ber u

niqu

e to

the

Faci

lity

unde

r con

stru

ctio

n. O

ne e

xcep

tion

is to

use

sta

tion

num

bers

for r

emot

e aq

uedu

ct e

quip

men

t tha

t are

not

lo

cate

d at

a D

istri

ct fa

cilit

y.

Ente

red

by c

ontr

acto

r.A

two-

or t

hree

-lette

r cod

e us

ed to

iden

tify

the

prim

ary

syst

em to

whi

ch th

e eq

uipm

ent i

s as

soci

ated

. Thi

s is

foun

d in

the

refe

renc

ed d

raw

ing

of s

yste

m c

odes

an

d na

mes

- 94

92-G

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.EQ

UIP

ME

NT

TAG

NU

MB

ER

CO

DE

S A

ND

CO

LOR

S.

Ente

red

by c

ontr

acto

r.Th

is is

the

two-

or t

hree

-lette

r cod

e us

ed to

iden

tify

the

equi

pmen

t typ

e or

func

tion.

Ref

er to

Equ

ipm

ent C

odes

tabl

e on

dra

win

g 94

92-G

-006

for a

list

ing

of

com

mon

equ

ipm

ent c

odes

.

Ente

red

by c

ontr

acto

r.Th

e E

quip

men

t ide

ntifi

catio

n ( I

D )

num

ber i

s a

thre

e-di

git n

umbe

r tha

t ind

icat

es a

trai

n nu

mbe

r for

trai

n-re

late

d ite

ms,

a lo

op n

umbe

r for

wire

d in

stru

men

ts, a

se

quen

ce n

umbe

r for

non

-trai

n or

non

-loop

rela

ted

item

s or

ele

ctric

al e

nclo

sure

num

ber f

or m

ount

ed e

lect

rical

equ

ipm

ent t

ypes

.

Ente

red

by c

ontr

acto

r.Th

e M

odifi

er is

a le

tter o

r num

ber u

p to

thre

e ch

arac

ters

that

iden

tifie

s th

e se

quen

ce n

umbe

r for

trai

n- a

nd lo

op-r

elat

ed e

quip

men

t, or

oth

er d

escr

ipto

r. A

m

odifi

er is

not

requ

ired

for a

ll eq

uipm

ent t

ag n

umbe

rs. M

ultip

le m

odifi

ers

may

be

adde

d.

2.TA

G C

REA

TIO

N D

ETA

ILS

NO

EN

TRY

NEE

DED

. Aut

o ge

nera

ted

from

the

abov

e ite

ms

1a th

roug

h 1e

. 'F

FFF-

SS

S-E

EE

-III

I-M

MM

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here

:FF

FF =

FA

CIL

ITY

NU

MB

ER

SS

S =

SY

STE

M C

OD

EE

EE

= E

QU

IPM

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T C

OD

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MM

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EQ

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ME

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UM

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R A

ND

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TIO

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L M

OD

IFIE

R

2b. E

QU

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NA

ME

Ente

red

by c

ontr

acto

r. N

OTE

: TH

IS F

IELD

IS L

IMIT

ED T

O 2

6 C

HA

RA

CTE

RS.

Bas

ic d

escr

iptio

n of

the

equi

pmen

t bei

ng ta

gged

. Som

e de

scrip

tion

in fr

ont o

f the

equ

ipm

ent t

ype

rela

ted

to it

s lo

catio

n or

func

tion

in th

e sy

stem

suc

h as

D

ISC

HA

RG

E P

RE

SS

UR

E S

WIT

CH

, UN

IT #

2 M

OTO

R S

TAR

TER

. S

ee th

e lis

t of e

xam

ples

in th

e A

sset

Upd

ate

Tem

plat

e.En

tere

d by

con

trac

tor.

Spe

cify

whe

ther

the

field

tag

will

be

form

atte

d as

'SS

T C

AB

LE' f

or c

abin

et ta

g or

'EP

OX

Y A

DH

ES

IVE

' for

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ging

tag

s (s

ee S

ectio

n 01

91

13.1

0 A

sset

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entif

icat

ion

Tags

for a

ttach

men

t req

uire

men

ts).

Ente

red

by c

ontr

acto

r.R

efer

ence

Sta

ndar

d D

raw

ing

- E

quip

men

t Tag

Num

ber C

odes

and

Col

ors

9492

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07.

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red

by c

ontr

acto

r.R

efer

ence

Sta

ndar

d D

raw

ing

- E

quip

men

t Tag

Num

ber C

odes

and

Col

ors

9492

-G-0

07.

This

fiel

d is

aut

omat

ical

ly fo

rmat

ted

and

crea

ted

by p

roce

edin

g fie

lds

and

shou

ld n

ot b

e m

anua

lly e

dite

d.

See

a li

st o

f exa

mpl

es o

n th

e A

sset

Lis

t Spr

eads

heet

.3.

ASS

ET N

AM

E

2a. E

QU

IPM

ENT

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2c. T

AG

ATT

AC

HM

ENT

TYPE

2

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R

2

e. B

AC

KG

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D C

OLO

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1

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ode

( SSS

)

1

c. E

quip

men

t Cod

e ( E

EE )

1

d. E

quip

men

t ID

num

ber (

IIII

)

1

e. O

ptio

nal M

odifi

ers

( MM

M )

INST

RU

CTI

ON

S FO

R C

OM

PLET

ING

TH

E A

SSET

LIS

T SP

REA

DSH

EET

The

prim

ary

use

of th

e A

sset

Lis

t Spr

eads

heet

is fo

r inp

ut o

f fie

ld e

quip

men

t and

met

a-da

ta in

to th

e E

BM

UD

wor

k m

anag

emen

t sys

tem

. Mos

t fie

lds

foun

d in

the

Ass

et L

ist S

prea

dshe

et w

ill b

e en

tere

d as

sea

rcha

ble

data

for e

nd-u

sers

so

accu

racy

and

use

of r

efer

ence

d do

cum

ents

( su

ch a

s E

quip

men

t Tag

Num

berin

g C

odes

) ar

e im

porta

nt.

1.EQ

UIP

MEN

T TA

G N

UM

BER

ING

DET

AIL

S

1

a. F

acili

ty N

umbe

r ( F

FFF

)

A-

Pag

e 2

of 2

Ente

red

by D

istr

ict.

Par

ent e

quip

men

t can

be

a ph

ysic

al e

nclo

sure

suc

h as

a v

ault

or e

lect

rical

pan

el th

at c

onta

ins

asse

ts a

s 'c

hild

ren'

. P

aren

t equ

ipm

ent m

ay a

lso

be fu

nctio

nal

in-n

atur

e fo

r exa

mpl

e a

Pum

p be

ing

the

pare

nt to

the

mot

or a

nd in

stru

men

ts a

nd v

alve

s co

ntai

ned

on th

at tr

ain;

inst

rum

ent l

oops

whe

re th

e pa

rent

is th

e pr

imar

y in

dica

tor s

uch

as a

pre

ssur

e or

flow

tran

smitt

ers.

This

fiel

d is

aut

omat

ical

ly fo

rmat

ted

and

crea

ted

by p

roce

edin

g fie

lds

and

shou

ld n

ot b

e m

anua

lly e

dite

d.

See

a li

st o

f exa

mpl

es o

n th

e A

sset

Lis

t Spr

eads

heet

.Th

is fi

eld

is a

utom

atic

ally

form

atte

d an

d cr

eate

d by

pro

ceed

ing

field

s an

d sh

ould

not

be

man

ually

edi

ted.

S

ee a

list

of e

xam

ples

on

the

Ass

et L

ist S

prea

dshe

et.

Ente

red

by c

ontr

acto

r.Th

is is

the

antic

ipat

ed d

ate

that

the

faci

lity

will

be

oper

atio

nally

read

y. F

orm

at s

houl

d be

MM

/ D

D /

YY

YY

. The

act

ual i

n-se

rvic

e da

te s

hall

be a

fter a

ll te

stin

g ha

s be

en c

ompl

eted

incl

udin

g th

e st

artu

p te

st.

Ente

red

by c

ontr

acto

r.Th

is is

the

phys

ical

loca

tion

of th

e lis

ted

Equ

ipm

ent.

It w

ill b

e us

ed to

ass

ist i

n lo

catin

g th

e as

set a

nd is

ver

y va

luab

le. I

f the

ass

et is

diff

icul

t to

loca

te p

hysi

cally

or

vis

ually

, thi

s fie

ld c

an b

e as

spe

cific

as

nece

ssar

y.

Exa

mpl

es m

ay b

e Fa

cilit

y B

uild

ing

or ro

om n

ame,

stre

et c

ross

ings

, phy

sica

l acc

ess

desc

riptio

n i.e

. acc

ess

via

6th

floor

util

ity ro

om v

entil

atio

n et

c.

This

fiel

d le

ngth

is li

mite

d to

100

cha

ract

ers.

Ente

red

by c

ontr

acto

r.Th

e dr

awin

g nu

mbe

r tha

t sho

ws

the

Equ

ipm

ent T

ag. T

ypic

ally

list

ed o

n E

quip

men

t P&

ID o

r ele

ctric

al s

ingl

e-lin

e dr

awin

gs.

Ente

red

by c

ontr

acto

r.Th

is is

the

Man

ufac

ture

r Nam

e of

the

equi

pmen

t bei

ng li

sted

. Th

is fi

eld

is li

mite

d to

25

char

acte

rs.

Ente

red

by c

ontr

acto

r.Th

is is

the

Mod

el N

umbe

r of t

he e

quip

men

t bei

ng li

sted

. The

ser

ial n

umbe

r is

not t

o be

list

ed in

this

are

a.

Ente

red

by c

ontr

acto

r.Th

is is

the

Man

ufac

ture

r's S

eria

l Num

ber f

or th

e eq

uipm

ent b

eing

list

ed.

Ente

red

by c

ontr

acto

r.Th

is is

the

equi

pmen

t pric

e fo

und

on th

e B

OM

, for

exa

mpl

e. N

o sp

ecia

l cha

ract

ers

shou

ld b

e in

clud

ed in

this

fiel

d; n

o $,

com

ma

or d

ecim

als.

For

exa

mpl

e,

$3,5

00.2

4 sh

ould

be

ente

red

as 3

500.

The

pric

e sh

ould

onl

y be

for t

he e

quip

men

t bei

ng re

fere

nced

in th

e E

quip

men

t Nam

e fie

ld.

Ente

red

by c

ontr

acto

r.V

endo

r nam

e as

indi

cate

d fo

r the

pro

ject

. En

tere

d by

con

trac

tor.

Con

tact

pho

ne n

umbe

r for

the

vend

or li

sted

abo

ve.

Ente

red

by c

ontr

acto

r.C

onta

ct n

ame

for t

he v

endo

r lis

ted

abov

e.

Ente

red

by c

onst

ruct

ion

staf

f.Th

is is

the

war

rant

y ex

pira

tion

date

that

is s

peci

fied

per t

he c

ontra

ct. L

abel

as

MM

/ D

D /

YY

YY

.

14.V

END

OR

CO

NTA

CT

NA

ME

15.W

AR

RA

NTY

EXP

IRA

TIO

N D

ATE

10.S

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11.P

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CH

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12.V

END

OR

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ME

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END

OR

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6.A

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N

7.D

RA

WIN

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UM

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AN

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MEN

T M

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4a. P

AR

ENT

EQU

IPM

ENT

TAG

#

4

b. S

YSTE

M T

AG

#

4

c. P

AR

ENT

FAC

ILIT

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5.IN

-SER

VIC

E D

ATE

INST

RU

CTI

ON

S FO

R C

OM

PLET

ING

TH

E A

SSET

LIS

T SP

REA

DSH

EET

- Con

tinue

d

Item

s 4

thro

ugh

15 a

re n

eces

sary

for c

ompl

etio

n of

the

final

Ass

et L

ist S

prea

dshe

et.

4.EQ

UIP

MEN

T H

IER

AR

CH

Y PL

AC

EMEN

T

A-2

3A

-23

MANUFACTURER’S CERTIFICATE OF PROPER INSTALLATION

OWNER:______________________________ EQPT SERIAL NO.:_____________________

EQPT TAG NO.:________________________ EQPT/SYSTEM:________________________

PROJECT NO.:_________________________ SPEC. & SECTION:_____________________

I hereby certify that the above-referenced equipment/system has been:

Complete Not Applicable

Installed in accordance with Manufacturer’s recommendations.

Inspected, checked, and adjusted.

Serviced with proper initial lubricants.

Electrical and mechanical connections meet quality and safety standards.

All system instruments are calibrated.

All applicable safety equipment has been properly installed.

Comments:_____________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

______________________________________________________________________________________

I, the undersigned Manufacturer’s Representative, hereby certify that I am (i) a duly authorized representative of the manufacturer, (ii) empowered by the manufacturer to inspect, approve, and operate the equipment and (iii) authorized to make recommendations required to assure that the equipment furnished by the manufacturer is complete and ready for startup and operations. I further certify that all information contained herein is true and accurate.

Date: ____________________________

Manufacturer: __________________________________________________________________

By Manufacturer’s Authorized Representative: ________________________________________ (Authorized Signature)

Manufacturer’s Certificate05/01/06 A- of Proper Installation

A-

Attachment A SAFE WORK PERMIT

Safe Work Permit

Location: Work Started Description of Work: Date:

Time:

Person Requesting Work:_________________________ Facility Representative:___________________________________

Personal Protective Equip : ______________________ _____________________________________________

EmergencyProcedures:___________________________________ ______________________________________________________

# SITUATION/CONDITION YES NO Maint. Initials

Unit Initials

WORK COMPLETED

Comments and Operations and Special Conditions:

Copies to: ORIGINAL to: Facility (Facility shall retain original for 90 days from date of work completion) YELLOW to: Maintenance (MS 55) PINK to: Water Treatment (MS 72) Goldenrod to: WHS (MS 704)

01/11/05

2047 Appendix A

O&M MANUAL REVIEW CHECKLIST(Manufacturer’s Representative to complete one form per submittal)

SPEC. SECTION TITLE & NO:

MFR Name, Address, Phone:

Local Rep Name, Address, Phone:

GENERAL FORMAT (See Section 01 33 00 for additional details)

DESCRIPTION PROVIDED?

COMMENTS YES NO

Specified copies provided

Binder cover clearly labeled

Spine Label

System/Equipment type clearly identified

District facility or facilities name(s) identified

Specification number & title shown

Title page provided

Equipment tag numbers correctly shown

Manufacturer’s name, address, phone number provided

Local Representative’s name, address, phone number provided

Table of contents provided

Heavy section dividers w/ numbered or lettered plastic tabs provided

Pages punched for 3-ring binder

Info larger than 8-1/2 x 11 folded showing title block

Original quality copies provided

TECHNICAL CONTENT (See Section 01330 for details)

DESCRIPTIONLOCATION IN O&M

COMMENTS TAB# PAGES N/A

Equipment DescriptionsEquipment names, model numbers & tag numbers

Equipment & major component functions

Drawings, diagrams & illustrations

Equipment Specification

Bill of materials

Performance InformationNameplate data

Performance test data/curves

Installation InstructionsInstallation procedures & drawings

07/02/12 O&M Manual 2047 A- 29 Review Checklist




Equipment tolerances

Adjustment procedures

Operating InstructionsStartup procedures

Normal & routine operations

Control functions

Alarms description and settings

Shutdown procedures

Emergency operations

Electrical Information

Nameplate data

Relay, control, alarm contact settings

Motor test data

Electrical DrawingsSingle-line diagrams, three-line diagrams

Interconnection wiring diagram

Schematic and elementary diagrams

Panel layout drawings

Instrumentation & ControlControl diagrams

Panel layout drawings

Instrument data sheets (specification forms)

Calibration Procedures

Final settings for adjustable control devices

Block diagrams and riser diagrams

Loop diagrams

Pneumatic/Hydraulic piping drawings

Hard copy printouts of control programs

Field calibration data sheets

Programming software (licensed to EBMUD) withuser manuals

Shipping and Storage InstructionsTesting

Factory Test Report (procedures and results)

Field Test Procedures

Manufacturer’s Certificate of Proper Installation(where specified)

Field Test Results

Troubleshooting guide

07/02/12 O&M Manual 2047 A- Review Checklist




Safety Safety procedures/Lockout discussion

CAUTION, WARNING, DANGER text

Material Safety Data Sheets (MSDS)

Special safety equipment

Preventive MaintenanceMaintenance Summary Forms

Lubrication InformationLocation of lube points & frequency

Recommended type & grade, state specific MFR

Recommended viscosity & temperature range

Overhaul InstructionsDetailed assembly drawings w/OEM part numbers

Tear down/rebuild instructions

Spare Parts for Equipment & ComponentsPredicted life of parts subject to wear or aging

Recommended spare parts list w/ part numbers

Complete instructions for obtaining parts

Long-term storage requirements

Special tools

Long-term Shutdown/Lay-up Instructions

Warranty/Guarantee

07/02/12 O&M Manual 2047 A- Review Checklist

05/13/10 Typical MaintenanceA- Summary Form

TYPICAL MAINTENANCE SUMMARY FORM (Use as many pages as necessary. MS Word file available upon request)

1. Equipment Name:

2. Manufacturer:

3. Identification Numbers:

Tag:

Model:

Serial:

4. Nameplate Data (HP, voltage, speed, flow rate, head, etc.):

5. Manufacturer’s Local Representative:

Name:

Telephone:

Address:

6. LUBRICANT LISTReference Symbol Lubricant Description

List symbols used in Item 8 below

List equivalent lubricants: brand name(s), type, grade, viscosity, etc.

7. SPARE PARTS (Recommendation spare parts with part numbers; if any.)

8. Equipment Replacement Cost [$] ____________________________________

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FLUSHING AND CHLORINATION CHECKLIST

Contractor’s Plan, as a minimum, shall address the following items:

FLUSHING PHASE

· Identify location of discharges· Indicate where discharge is going (truck, tank, storm drain, sewer)· If sewer, provide approval by sanitary district· Mention whether or not flow goes into waterway (if yes, indicate discharge distance)· Indicate location of monitoring/test points on source main· Specify feed size· Indicate number and size of blowoffs and hoses attached to blowoffs· Calculate estimated flush rate (gal/min) and flush time· Test and record source main results

CHLORINATION PHASE

· Identify who will be doing the chlorinating· Indicate number of trained contractor personnel to be present· Specify pump to be used· Indicate method of testing for chlorine residue· Calculate estimated time to chlorinate and amount of chlorine to be used· Specify method of verifying no chlorine intrusion to the source main· Indicate sequence of valve operation where applicable· Indicate method of communication· During and after chlorination, test and record source main results

DECHLORINATION PHASE

· Specify dechlorination method· Indicate location of disposal· Indicate method of testing for chlorine residue, and record test results

During all phases of flushing, pH levels shall not drop below 6.5 or rise above 8.5.

02/28/02A- Appendix A

TRAINING EVALUATION

Thank you for your time and cooperation in completing this course evaluation. Please answer all questions honestly. Your response will help in improving, if necessary, and planning future programs. We want to know what you think. Please print or write legibly.

Employee Name Job Title (optional)

Workshop Title Date

Instructor Location

Check only one appropriate for each question.

EXCELLENTABOVE

AVERAGE AVERAGEBELOW

AVERAGE POOR5 4 3 2 1

1. Quality of course content.........................................................

2. Organization of course content................................................

3. Ability to use the course material in your job ...........................

4. How much you learned from the training .................................

5. Instructor’s knowledge of the topic ..........................................

6. Instructor’s ability to communicate courseinformation to you ....................................................................

7. Instructor’s ability to hold your interest duringthe training...............................................................................

8. Instructor’s presentation methods............................................

9. Overall instructor rating............................................................

10. Overall worth of training...........................................................

The training can be improved by:

What I liked most about the training was:

I will apply the material learned to my job in these ways

Would you recommend this training to fellow employees (same classification)? Yes No

Why or why not?

UF010-51.doc Q-025 8/98

02/28/02A- Appendix A

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Photo Confidentiality AgreementSpecification 2047

1. Contractor agrees to not distribute any construction photographs, images or videoof this construction project to outside or third parties, except with anysubcontractors, suppliers or others directly involved with the project.

2. Contractor agrees that written consent of Engineer must be obtained prior todistribution of photographs, images, or video to outside third parties. This needfor prior written consent includes, but is not limited to: publications or tradejournals, public relations displays, magazine articles and other media available tothe public.

3. Contractor agrees to exercise reasonable and prudent precautions and securitymeasures to protect the integrity and confidentiality of all photographs, imagesand video taken of the construction project.

Firm: ___________________________________

By (Signature): ____________________________

Title*: ___________________________________

Address: ________________________________

________________________________________

________________________________________

Phone: _________________________________

Date: ___________________________________

* Must be owner or officer of corporation

08/19/13 2047 A-45 Appendix A

APPENDIX B

MATERIALS ASSESSMENT TESTING

Includes laboratory testing results for lead based paint and asbestos.

1. EBMUD, Almond Pumping Plant Demolition Project Lead and Asbestos Survey,dated February 2, 2012.

2. PES Environmental, Results of Preliminary Field Screening InvestigationsEBMUD Reservoir, Pump and Filter Facilities Alameda and Contra Costa Counties, dated November 4, 1994.

3. EBMUD, Analytical Report dated May 31, 2012.

08/19/13 Appendix B 2047

EAST BAY MUNICIPAL UTILITY DISTRICT

DATE February 2, 2012

MEMO TO: Tom Boardman, Associate Civil Engineer

FROM: Sandra R. Beecher, Sr. Environmental Health and Safety Specialist

SUBJECT: Almond Pumping Plant Demolition Project Lead and Asbestos Survey

INTRODUCTION

The Almond Pumping Plant is going to be demolished. In preparation for this demolition, several bulk samples for lead and asbestos were taken.

RECOMMENDATIONS

Based on the current work plan, please implement the following: Inform the contractor of the results in the table below.

DISCUSSION (RESULTS) Sample results from the lead and asbestos survey conducted in the office area are below.

Date Sampled

Location Material Analyte Results

1/13/2012 Red paint on floor Paint Chip Lead 1700 mg/kg 1/13/2012 Yellow paint on Motor Paint Chip Lead 196 mg/kg 1/13/2012 Brown paint on inside

door Paint Chip Lead 17200 mg/kg

1/13/2012 White paint on floor Paint Chip lead 118 mg/kg 1/13/2012 Grey paint on pedestal Paint Chip lead 3680 mg/kg 1/13/2012 Brown paint on outside

of building Paint Chip Lead 34800 mg/kg

1/13/2012 Green paint on outside of building

Paint Chip Lead 1740 mg/kg

1/13/2012 Red paint on outside pipe

Paint Chip Lead 1770 mg/kg

1/13/2012 Roof Tile Piece of roof asbestos Non-detected1/13/2012 Outside pipe tar asbestos Non-detected 1/13/2012 Outside of building Silver tape asbestos Non-detected 1/13/2012 Outside concrete

platform Expansion joint material asbestos Non-detected

Unit #1, #2 Starter Cabinets

Arc chutes, black Arc chutes, black Arc chutes, black Arc chutes, black mesh cable

Asbestos WHS visual inspection (Suspected asbestos)

Archive Info Ceiling Paint Chip Lead 5450 mg/kg Archive Info Pipes Paint Chip Lead 2460 mg/kg Archive Info Wall Paint Chip Lead 5750 mg/kg Archive Info Motor Paint Chip Lead 24.1 mg/kg

EAST BAY MUNICIPAL UTILITY DISTRICTLaboratory Services DivisionPhone (510)287-1432 Fax (510)465-5462PO Box 24055, MS 59, Oakland, CA 94623

Reported by: Approved by:

Analytical Report Prepared for SANDY BEECHER

Report generated on: May 31, 2012 03:42 pmLogin No.: L175357

___________________________________ ___________________________________ KENNETH GERSTMAN NIRMELA ARSEM Laboratory Program Manager Laboratory Services Division Manager

LSR B784-0706-1Project Title: Analytical Support for the Workplace Health and Safety Section - Water System

Login Performance Summary2 - Samples received by the lab on: May 17 2012, 01:49 pm0 - Lost Analyses0 - Hold Time ExceedencesTurn-around-time met

Samples included in this report: Sample Type Collected Site Locator ClientID L175357-1 GRAB 14-May-2012 10:00 MISC MISC 1JC5/14/12 El Portal valve pit Lead L175357-2 GRAB 14-May-2012 10:15 MISC MISC 2JC5/14/12 El Portal valve pit Lead

Legend to the laboratory qualifiers used in this report:No qualifiers are included in this report

California Environmental Laboratory Accreditation Program Certificate Number 1060

Page 1 of 3

EAST BAY MUNICIPAL UTILITY DISTRICT Laboratory Services Division PO Box 24055, MS 59, Oakland, CA 94623 Phone (510)287-1432 Fax (510)465-5462

Analytical Results Report

LSR B784-0706-1 Analytical Support for the Workplace Health and Safety Section -Site: MISC Miscellaneous - Unidentified SiteLocator: MISC Miscellaneous sample, see sample comments for locationClientID: 1JC5/14/12 El Portal valve pit LeadLab ID: L175357-1 (P181957-1) Rush - 10 working daysSample Type: GRAB (Instantaneous Grab)Date Collected: May 14 2012, 10:00am Sample collector: SBeecherDate Received: May 17 2012, 01:49pm Sample receiver: DNGSample Comments: 1JC5/14/12 El Portal valve pit - valve pit lead - Black paint on motor

Method Reference Matrix TagParameter Qualifier Result Units Dilution MDL RL/ML

Method: EPA 6010 - ICP Scan MiscSolidTARGET ANALYTESLEAD 570 mg/kg .746 5.97Run ID: R228862 / Work Group No.: WG176712Prep Date1: 31-MAY-12 Analyzed 31-May-12 10:23

RL is either the client requested or regulatory mandated Reporting Limit. ML is the regulatory mandated Minimum Level

Page 2 of 3

EAST BAY MUNICIPAL UTILITY DISTRICT Laboratory Services Division PO Box 24055, MS 59, Oakland, CA 94623 Phone (510)287-1432 Fax (510)465-5462

Analytical Results Report

LSR B784-0706-1 Analytical Support for the Workplace Health and Safety Section -Site: MISC Miscellaneous - Unidentified SiteLocator: MISC Miscellaneous sample, see sample comments for locationClientID: 2JC5/14/12 El Portal valve pit LeadLab ID: L175357-2 (P181957-2) Rush - 10 working daysSample Type: GRAB (Instantaneous Grab)Date Collected: May 14 2012, 10:15am Sample collector: SBeecherDate Received: May 17 2012, 01:49pm Sample receiver: DNGSample Comments: 2JC5/14/12 El Portal valve pit - Black paint on Valve Pit Piping

Method Reference Matrix TagParameter Qualifier Result Units Dilution MDL RL/ML

Method: EPA 6010 - ICP Scan MiscSolidTARGET ANALYTESLEAD 37.4 mg/kg .556 4.44Run ID: R228862 / Work Group No.: WG176712Prep Date1: 31-MAY-12 Analyzed 31-May-12 10:26

RL is either the client requested or regulatory mandated Reporting Limit. ML is the regulatory mandated Minimum Level

Page 3 of 3

A P P E N D I X C

LISTING OF SOLE-SOURCED PRODUCTS SPECIFIED IN THE CONTRACT DOCUMENTS

08/19/13 Appendix C2047

A P P E N D I X C

LISTING OF SOLE-SOURCED PRODUCTS SPECIFIEDIN THE CONTRACT DOCUMENTS

Specification Section

Product Reason for Selection

26 05 26 –Grounding and Bonding for Electrical Systems

Deutsche GroundLok radial swage connectors

This product is the only compression connector approved in the PG&E Interconnection Handbook, Drawing #067910 “Grounding Requirements for Outdoor Electrical Substations”.

Note that we have also allowed exothermic welded connections for the same application as the Deutsche GroundLok radial swage connectors and have listed two acceptable manufacturers or equal for the exothermic welded connections.

26 09 13 –Electrical Power Monitoring and Control

Electro Industries, Nexus 1272,part number 1272-A-SWB2-20-60-DE-INP202-COMEXT3.MC

Electro Industries, optical probe,part number A9U.

The specified product is needed for operational compatibility with the existing power monitoring, control, and communication system used by the District.

27 21 16 – Data Communications Routers, CSU/DSU, Multiplexers, Codecs, and Modems

Synxcom leased line modem, for RTU lease line, part number SM19202FP-K-DIN, V2.10 or above.

The specified product is needed for operational compatibility with the existing communication system used by the District.

33 09 70 –Instrumentation and Control for ElectricalUtilities

Wonderware Upg, Development Studio Large 5000 / 3000 / 1000

Wonderware Upg, Wonderware Historian Server Standard, 1000 Tag.

The specified product is a license upgradeand training for software that the District already owns. The specified product is needed for operational compatibility with the existing power monitoring, control, and communication system used by the District.

08/19/132047 Appendix C

33 72 33 –Control House Equipment

Schweitzer Engineering Laboratories, multifunction motor protection relay, Type SEL 710, part number 071001ACA5X72820201.



Schweitzer Engineering Laboratories, overcurrent relay, Type SEL 501-2, part number 05012W32561PXB2.



Schweitzer Engineering Laboratories, fiber-optic RTD transmitter, Type SEL 2600A, part number 2600A01X.



Schweitzer Engineering Laboratories, bus differential relay, Type SEL-587Z, part number 0587Z02225H12XX.



Schweitzer Engineering Laboratories, GPS clock, Type SEL-2407 and related accessories.



Novatech Orion LXcommunications processor, part number OrionLX-A14-B2-ENEN-MDM-CPX-MMB-XM4-IHV-HV-HVxx-01-03-04-07-14-32-42-44-47-49-57-81-94-95-96-99 and related accessories.



Schweitzer Engineering Laboratories, I/O processor, Type SEL-2411, part number 241102C3C2X3C3C1101.


08/19/132047 Appendix C


Schweitzer Engineering Laboratories, fiber-optic transceiver and modem, Type SEL 2812MT and Type SEL 2812MR.



Schweitzer Engineering Laboratories, EIA-232 to EIA-485 interface converter, Type SEL 2886.



Schweitzer Engineering Laboratories, Ethernet security gateway, Type SEL 3620, part number 3620XHB0XXX1.



Schweitzer Engineering Laboratories, relay test source, Type SEL-4000.



Schweitzer Engineering Laboratories, relay data courier, Type SEL-4391.



Schweitzer Engineering Laboratories, arc-flash test module, Type SEL-4520.



Schweitzer Engineering Laboratories, relay database management software, Type SEL-5010.



Schweitzer Engineering Laboratories, relay event report analysis software, Type SEL-5601.


08/19/132047 Appendix C

40 94 33 –Operator Interface Units

Maple Systems, part number HMI5150P, with PLC connecting cable, part number 7446-0137-5,USB configuration cable, part number 7431-0115, and windows-based configuration software, part number EZware.


40 94 43 –Programmable Logic Process Controllers

Programmable Logic Controller (PLC): Rockwell Automation MicroLogix 1400 1766-L32BXBA



PLC Modbus RS-485Communication Adapter:Rockwell Automation Memory Module 1763-NC01.



PLC Memory Module: Provide one memory module for each MicroLogix PLC supplied in this specification. Rockwell Automation Memory Module 1766-MM1



PLC 4 Channel Analog Input Expansion Module: Rockwell Automation MicroLogix 1400 1762-IF4



PLC Programming Software:Rockwell Automation RSLogix 500 Standard Edition, 9324-RL0300ENE.



PLC Interface Cables: Rockwell Automation 1761-CBL-PM02and 1747-CP3.



Remote Telemetry Unit (RTU): Control Microsystems SCADAPack TBUP357-1A20-AB20



RTU Interface Cables: Control Microsystems TBUM297218 and TBUM297217.


08/19/132047 Appendix C

A P P E N D I X D

ALAMEDA COUNTYENCROACHMENT PERMIT FORMS

AND TRAFFIC CONTROL PLAN

08/19/13 Appendix D2047

Work Order Number:*

Permit Number:

*This WO is ____ / is not _____ open for charges. Permit Issuance Date:__________________ Permit Expiration Date:

COUNTY OF ALAMEDA PUBLIC WORKS AGENCY ROADWAY ENCROACHMENT PERMIT

This Permit is issued in accordance with Chapter 12.08 of the Alameda County General Ordinance Code Name & Address of Property Owner: Job Site Address: ____________________________________ _____________________________________ ____________________________________ _____________________________________ ____________________________________ Phone Number: (This statement to be completed by the Agency)

Name & Address of Contractor: This permit is issued to the owner __ / contractor __ ; ____________________________________ if “owner” is checked, he/she is __ / is not ___exempt ____________________________________ from the requirement that work in the roadway be ____________________________________ performed by a licensed contractor. Phone Number:

The Applicant intends to perform the following work scope: Licensed Contractor Declaration: Worker’s Compensation Insurance Declaration: I hereby affirm, under penalty of perjury, that I hold the following contractor’s license, which is in full force and effect, under the applicable provisions of the State Business and Professions Code.

I hereby affirm, under penalty of perjury, that I will, during the performance of any and all work authorized by this permit, satisfy the requirements of the State Labor Code with regard to Worker’s Compensation Insurance, as declared below:

License Class and No. ___ I will maintain a certificate of consent to self-insure. Contractor’s Signature: ___ I will maintain the following insurance policy: Carrier’s Name and Policy No.:

___ I will not employ any person in any manner so as to become subject to the worker’s compensation laws of the State.

Owner’s/Contractor’s Signature:

All work and/or access shall be performed in accordance with the requirements of Chapter 12.08 and, unless otherwise specified below, shall be fully compliant with each of the terms and conditions of the attached General Provisions: ______________________________________________________________________________ Bond Information:

Insp. Fee ___ or Deposit ___:

BY:__________________, Alameda County

Work Completed (Date):________________ Inspector:

I certify that the information that I have entered into this permit application is correct, and I agree to comply with all of the terms and conditions and other requirements of the issued Permit. _____________________________________________ ___________________ Signature of Applicant Date

THIS PERMIT IS INCOMPLETE WITHOUT THE ATTACHED GENERAL PROVISIONS

CALL THIS NUMBER FOR INSPECTIONS:

INSPECTION REQUIREMENTS All encroachments authorized by this Permit shall be subject to monitoring, inspection, and/or

testing by a County representative; notify the County before you start work by calling the number on the front of this form.

If the face of this Permit is marked to indicate that the assigned County work order is open for charges, a

job account will be opened and the assigned inspectors and other representatives will charge the actual cost of all required tests and inspections against this account. All cost overruns must be resolved prior to closeout of this Permit. Any underruns will be returned to the Permittee as soon as possible following the closeout.

Revised 4/1/04

CAUTION!

Most traffic signals and some streetlights are connected to their power sources with underground wiring. Many signals are also wired to traffic detector loops buried in the roadway. None of these County-owned wiring runs are included in the Underground Service Alert (USA) review and marking processes. If you intend to excavate within 500’ of a traffic signal, or in proximity to County-owned

streetlights, you must contact the County traffic signal maintenance office at →(510) 670 - 5537←

at least 48 hours in advance of the start of your planned work.

If you cause a signal outage, a streetlight failure, or other damage to County signal or streetlight facilities because you failed to contact the signal office to get the facilities marked, you will be billed for the full cost of our emergency response and repairs.

Final Road Closure Analysis

Report

Almond Pumping Plant Replacement Project in CastroValley Prepared for

East Bay Municipal Utility District (EBMUD)

Prepared By

1970 Broadway, Suite 740Oakland, CA 94612(510) 763 2061

April 16, 2013

Final Road Closure Analysis Report for the EBMUDAlmond Pumping Plant Replacement Project in CastroValley

i April 16, 2013

Table of ContentsROAD CLOSURE ANALYSIS REPORT.......................................................................................... 2

INTRODUCTION............................................................................................................................... 2EXISTING TRAFFIC CONDITIONS...................................................................................................... 2

Roadway Network .................................................................................................................... 2Traffic Volumes ........................................................................................................................ 2

ROAD CLOSURE ANALYSIS............................................................................................................... 5TRAFFIC CONTROL PLAN................................................................................................................. 5SUMMARY AND RECOMMENDATIONS......................................................................................... 11

STUDY PARTICIPANTS............................................................................................................ 12

DKS PERSONNEL............................................................................................................................ 12OTHERS ............................................................................................................................... .......... 12REFERENCES ............................................................................................................................... ... 12

List of AppendicesAPPENDIX A – 24 HOUR WEEKDAY TRAFFIC COUNTSAPPENDIX B – TRAFFIC DETOUR AND CONTROL PLANS

List of FiguresFigure 1: Project Location ............................................................................................................... 3Figure 2: Traffic Volumes ................................................................................................................ 4Figure 3: Detour route for 173rd Avenue road closure between Ehle Street and Roberto Street 8Figure 4: Detour route for 173rd Avenue road closure between Roberto Street and Robey Drive 9Figure 5: Detour route for Robey Drive/174th Avenue road closure between 173rd Avenue and

President Drive....................................................................................................................... 10

p:\p\11\11037-001 ebmud castro valley almond road pumping plant replacement project\report\report 010413.docx


2 April 16, 2013

ROAD CLOSURE ANALYSIS REPORT

IntroductionEast Bay Municipal Utility District (EBMUD) has retained DKS Associates to analyze traffic impactand develop traffic control design for the Almond Pumping Plant Replacement Project in theunincorporated area of Castro Valley in Alameda County. EBMUD plans to replace the existingpipelines along 173rd Avenue and 174th Avenue in Castro Valley to increase the flow capacity tothe new pumping plant. The pipeline construction will include the following:

1500 feet of 36” diameter pipeline located along 173rd Avenue from Ehle Street toRobey Drive and continuing located along Robey Drive/174th Avenue to President Drive.

700 feet of 6” diameter pipeline located along Robey Drive/174th Avenue from 173rdAvenue to President Drive.

800 feet of 2” diameter pipeline located along Robey Drive/174th Avenue from 173rdAvenue to President Drive.

This construction project will require roadway closure to provide the work crews sufficient workspace and to protect the public from the work zone. The primary goal of the road closure analysisis to develop traffic circulation, control, and construction phasing plans to minimize constructionimpacts to local residents in the project area. Also, the objective of the analysis is to provideaccess to/from private residence during the duration of the construction.

Figure 1 shows the project limit and location.

Existing Traffic Conditions

Roadway Network173rd Avenue is a narrow (i.e. approximately 24 feet to 27 feet wide) two lane north southresidential collector street in Castro Valley. Parking is allowed on both sides of the street, whichreduces the effective width of the roadway for traffic flow. 173rd Avenue extends northerly fromFoothill Boulevard and terminates at Robey Drive. 173rd Avenue carries approximately 466vehicles per day.

Robey Drive/174th Avenue is a narrow (i.e. approximately 18 – 24 feet wide) two lane windingresidential roadway in Castro Valley. Robey Avenue extends southerly to become 174th Avenue.Robey Drive/174th Avenue carries approximately 189 vehicles per day.

Traffic VolumesFigure 2 shows the weekday a.m. peak hour, p.m. peak hour, and daily directional traffic volumesfor 173rd Avenue and Robey Drive/174th Avenue. Quality Counts, a data collection firm,conducted the 24 hour counts on June 19, 2012. The purpose of conducting the traffic counts isto assess the potential impact of the road closures for the pipeline construction, and to identifytraffic impacts during peak periods. Appendix A contains the traffic counts. DKS staff visited theproject site to observe existing site conditions and traffic patterns.


5 April 16, 2013

Road Closure AnalysisAs noted, DKS staff conducted field review to determine if there are any opportunities to provideroom for traffic flow during construction. Typically, 36 inch pipeline require approximately 25 feetto 30 feet work zone width to accommodate construction equipment. This implies that it will notbe feasible to maintain one lane for traffic within the construction zone along 173rd Avenue and174th Avenue, which may impact local residents in the area.

Also, typical work production rate for installing a 36 inch pipeline is between 80 and 200 feet perday. However, it is conservative to assume a production rate of approximately 80 feet per daydue to the inherent challenges involved in installing pipelines along roadway segments with sharpcurves and bends. The production rate will determine the duration for the pipeline replacementproject and road closures.

In addition to pipeline construction, the roadway segments will need to be closed for servicetransfer, trench restoration, and road reconstruction/resurfacing activities.

Traffic Control PlanDKS has developed traffic detour plans and traffic control schemes to minimize traffic impact andinconvenience to local residents. It was determined from analyzing the 24 hour traffic volumesthat there are currently very low traffic (i.e. less than 40 vehicles per hour) on 173rd Avenue andRobey Drive/174th Avenue throughout the day. Therefore, it is recommended to extend the dailywork hours so as to increase the work production rate to shorten the construction duration. Thehours between 9:00 a.m. and 6:00 p.m. can be considered. The objective of shortening theconstruction duration is to minimize traffic impact to residents.

Figures 3, 4, and 5 show the traffic detour plans for the road closures for the pipelineconstruction. As shown in the figures, residents will have access to alternative routes to bypassthe construction area. The road closure for construction will be done in three phases (i.e. Phases1, 2, and 3) as shown on Plans TC 3, TC 4, and TC 5 respectively. The following paragraphsdescribe the details of the detour routes and recommendations to provide access to residentsaffected by the pipeline construction.

It is recommended to provide notification to residents regarding the proposed pipelinereplacement project. The notification should include the following:

1. The expected duration and date of completion of the construction,

2. On street parking permit from Alameda County, and

3. Detour maps to inform residents about alternative routes to bypass the construction workzones.

Additionally, whenever possible, residents will be allowed access to their homes by showingappropriate identification (ID). This can be done by deploying flaggers at both ends of theconstruction zones to check IDs. This solution is particularly relevant to the pipeline constructionalong Robey Drive/174th Avenue between 173rd Avenue and President Drive. The contractor maybe instructed to provide safe passage of vehicles through the construction work zone.


6 April 16, 2013

Also, to minimize inconvenience to residents, it is recommended to open the roadway for trafficat the end of each work day. The contractor will be required to cover the trenches with platesthat have adequate strength for the safe passage of vehicles, and park construction equipmenton the side of the road to create room for traffic.

Phase 1 Road ClosureFigure 3 shows the closure of 173rd Avenue between Ehle Street and Roberto Street for thepipeline construction. The length of the roadway segment is approximately 340 feet.

To conservatively estimate the construction duration for the pipeline installation in the roadwaysegment, a work production rate of 80 feet per day will result in completing the constructionwithin approximately five (5) days. As shown in Figure 3, local residents can use Ehle Street, 170th

Avenue, and Roberto Street to bypass the construction area. The applicable detailed trafficcontrol plans are shown on Plans TC 1, TC 2, and TC 3 contained in Appendix B.

Phase 2 Road ClosureFigure 4 shows the closure of 173rd Avenue between Roberto Street and Robey Drive for thepipeline construction. The length of the roadway segment is approximately 245 feet. Toconservatively estimate the construction duration for the pipeline installation in the roadwaysegment, a work production rate of 80 feet per day will result in completing the constructionwithin approximately four (4) days. As shown in Figure 4, local residents can use Ehle Street, 170th

Avenue, and Robey Drive to bypass the construction area. The applicable detailed traffic controlplan is shown on Plan TC 4 contained in Appendix B.

Phase 3 Road ClosureFigure 5 shows the closure of Robey Drive/174th Avenue between 173rd Avenue and PresidentDrive for the pipeline construction. There will be three road closures for this road segment withdurations described as follows:

3a. First Road Closure for Robey Dr/174th Ave

The road segment will be closed for pipeline installation. The length of the roadwaysegment is approximately 900 feet. To conservatively estimate the construction durationfor the pipeline installation in the roadway segment, a work production rate of 80 feet perday will result in completing the construction within approximately 12 days. With a workproduction rate of approximately 80 feet per day, it is expected that the actual work zonefor the construction equipment will be within 400 feet; therefore approximately 500 feetof the roadway should be accessible to local residents who live along Robey Drive/174thAvenue at any given time during construction. The residents will be allowed access byshowing appropriate identification. As shown in Figure 5, local residents can use 170thAvenue, 173rd Avenue, Roberto Street and President Drive to bypass the constructionarea.


7 April 16, 2013

3b. Second Road Closure for Robey Dr/174th AveA portion of the road will be closed to accommodate the transfer of service from the temporary2” pipeline to the 6” pipeline and Asphalt Concrete (AC) patching work. This construction activityis expected to last for duration of approximately five (5) days.

3c. Third Road Closure for Robey Dr/174th AveThe third road closure would include removing temporary Asphalt Concrete (AC) road surfaceand reconstructing new and permanent road pavement base and AC road surface. This activity isexpected to last for duration of approximately seven (7) days.

The applicable detailed traffic control plan is shown on Plan TC 5 contained in Appendix B.


11 April 16, 2013

Summary and Recommendations1. Typically, 36 inch pipeline require approximately 25 feet to 30 feet work zone width to

accommodate construction equipment. This implies that it will not be feasible to maintainone lane to traffic within the construction zone along 173rd Avenue and 174th Avenue,which may impact local residents in the area.

2. A typical work production rate for installing a 36 inch pipeline is approximately 80 feet perday based on the inherent challenges involved in installing pipelines along roadways withsharp curves and bends. The production rate will determine the duration for the pipelinereplacement project. The construction duration for the various pipeline segments isexpected to be completed as follows assuming a work production rate of 80 feet per day(i.e. conservative estimate):

173rd Avenue between Ehle Street and Roberto Street – approximately five (5)days.

o The tie in at 173rd Avenue/Ehle Street – approximately seven (7) days.

173rd Avenue between Roberto Street and Robey Drive – approximately four (4)days.

Robey Drive/174th Avenue between 173rd Avenue and President Drive –approximately 12 days.

o The tie in at 174th Street/President Drive – approximately seven (7) days.

3. It is recommended to provide notification to residents regarding the proposed pipelinereplacement project. The notification should include the following:

The expected duration and date of completion of the construction,

On street parking permit from Castro Valley, and

Detour maps to inform residents about alternative routes to bypass theconstruction work zones.

Portable changeable message sign (PCMS) located on each side of road closure.

4. Whenever possible, residents will be allowed access to their homes if they are locatedwithin a closed roadway segment. They will be allowed by showing appropriateidentification. The contractor may be instructed to provide safe passage of vehiclesthrough the construction work zone.

5. It is recommended to open the roadway for traffic at the end of each work day tominimize inconvenience to residents.

6. The contractor will be required to cover the trenches with plates that have adequatestrength for the safe passage of vehicles, and park construction equipment on the side ofthe road to create room for traffic.


12 April 16, 2013

STUDY PARTICIPANTS

DKS PersonnelThomas Krakow, P.E. Principal In ChargeDavid Mahama, P.E. Project ManagerAlex Ha, E.I.T. Transportation EngineerDeserae Mallori Word Processing and Graphic Designer

OthersMarshall McLeod EBMUDSerge Terentieff, P.E. EBMUDQuality Traffic Counts Data Collection

References1. ITE Manual of Transportation Engineering Studies

2. Manual of Uniform Traffic Control Devices (MUTCD)

Appendix A – 24 Hour Weekday Traffic Counts

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Pag

e 1

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Rep

ort g

ener

ated

on

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epor

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ount

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lity

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ts:

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ort g

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on

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30 P

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Type

of r

epor

t: Tu

be C

ount

- V

olum

e D

ata

SO

UR

CE

: Qua

lity

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nts,

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(http

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ww

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lityc

ount

s.ne

t)

LOC

ATI

ON

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4th

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bet

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n 17

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and

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side

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ft fro

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ts:

Pag

e 1

of 1

Rep

ort g

ener

ated

on

6/20

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2 4:

30 P

M

Appendix B – Traffic Detour and Control Plans

A P P E N D I X E

TITLE 22 REGULATED VOCS

08/19/13 Appendix E2047

EX

CE

RPT

[REH

1]-A

TT

AC

HM

EN

T 1

Regu

late

d C

onta

min

ants

with

PRI

MA

RY D

RIN

KIN

G W

ATE

R ST

AN

DA

RDS

Con

tam

inan

tU

nit

Mea

sure

men

t

MC

L[M

RD

L]

PHG

(MC

LG

)[M

RD

LG

]

Typ

ical

Sou

rce

of

Con

tam

inan

tH

ealth

Eff

ects

Lan

guag

e

Vol

atile

Org

anic

Con

tam

inan

tsB

enze

nepp

b1

0.15

Dis

char

ge fr

om p

last

ics,

dyes

and

ny

lon

fact

orie

s; le

achi

ng fr

om g

as

stor

age

tank

s and

land

fills

Som

e pe

ople

who

use

wat

er c

onta

inin

g be

nzen

e in

ex

cess

of t

he M

CL

over

man

y ye

ars m

ay e

xper

ienc

e an

emia

or a

dec

reas

e in

blo

od p

late

lets

, and

may

hav

e an

incr

ease

d ris

k of

get

ting

canc

er.

Car

bon

tetra

chlo

ride

ppt

500

100

Dis

char

ge fr

om c

hem

ical

pla

nts a

nd

othe

r ind

ustri

al a

ctiv

ities

Som

e pe

ople

who

use

wat

er c

onta

inin

g ca

rbon

te

trach

lorid

e in

exc

ess o

f the

MC

L ov

er m

any

year

s m

ay e

xper

ienc

e liv

er p

robl

ems a

nd m

ay h

ave

an

incr

ease

d ris

k of

get

ting

canc

er.

1,2-

Dic

hlor

oben

zene

ppb

600

600

Dis

char

ge fr

om in

dust

rial c

hem

ical

fa

ctor

ies

Som

e pe

ople

who

drin

k w

ater

con

tain

ing

1,2-

dich

loro

benz

ene

in e

xces

s of t

he M

CL

over

man

y ye

ars

may

exp

erie

nce

liver

, kid

ney,

or c

ircul

ator

y sy

stem

pr

oble

ms.

1,4-

Dic

hlor

oben

zene

ppb

56

Dis

char

ge fr

om in

dust

rial c

hem

ical

fa

ctor

ies

Som

e pe

ople

who

use

wat

er c

onta

inin

g 1.

4-di

chlo

robe

nzen

e in

exc

ess o

f the

MC

L ov

er m

any

year

s m

ay e

xper

ienc

e an

emia

, liv

er, k

idne

y, o

r spl

een

dam

age,

or c

hang

es in

thei

r blo

od.

1,1-

Dic

hlor

oeth

ane

ppb

53

Extra

ctio

n an

d de

grea

sing

solv

ent;

used

in th

e m

anuf

actu

re o

f ph

arm

aceu

tical

s, st

one,

cla

y, a

nd

glas

s pro

duct

s; fu

mig

ant

Som

e pe

ople

who

use

wat

er c

onta

inin

g 1,

1-di

chlo

roet

hane

in e

xces

s of t

he M

CL

over

man

y ye

ars

may

exp

erie

nce

nerv

ous s

yste

m o

r res

pira

tory

pro

blem

s.

1,2-

Dic

hlor

oeth

ane

ppt

500

400

Dis

char

ge fr

om in

dust

rial c

hem

ical

fa

ctor

ies

Som

e pe

ople

who

use

wat

er c

onta

inin

g 1,

2-di

chlo

roet

hane

in e

xces

s of t

he M

CL

over

man

y ye

ars

may

hav

e an

incr

ease

d ris

k of

get

ting

canc

er.

1,1-

Dic

hlor

oeth

ylen

epp

b6

10D

isch

arge

from

indu

stria

l che

mic

al

fact

orie

sSo

me

peop

le w

ho u

se w

ater

con

tain

ing

1,1-

dich

loro

ethy

lene

in e

xces

s of t

he M

CL

over

man

y ye

ars

may

exp

erie

nce

liver

pro

blem

s.ci

s-1,

2-D

ichl

oroe

thyl

ene

ppb

610

0D

isch

arge

from

indu

stria

l che

mic

al

fact

orie

s; m

ajor

bio

degr

adat

ion

bypr

oduc

t of T

CE

and

PCE

grou

ndw

ater

con

tam

inat

ion

Som

e pe

ople

who

use

wat

er c

onta

inin

g ci

s-1,

2-di

chlo

roet

hyle

ne in

exc

ess o

f the

MC

L ov

er m

any

year

s m

ay e

xper

ienc

e liv

er p

robl

ems.

2009

SW

S C

CR

Form

s &

Inst

ruct

ions

Revi

sed

Jan

2010

CC

R In

stru

ctio

ns –

Atta

chm

ents

1

Page

1of

3

Con

tam

inan

tU

nit

Mea

sure

men

t

MC

L[M

RD

L]

PHG

(MC

LG

)[M

RD

LG

]

Typ

ical

Sou

rce

of

Con

tam

inan

tH

ealth

Eff

ects

Lan

guag

e

trans

-1,2

-Dic

hlor

oeth

ylen

epp

b10

60D

isch

arge

from

indu

stria

l che

mic

al

fact

orie

s; m

inor

bio

degr

adat

ion

bypr

oduc

t of T

CE

and

PCE

grou

ndw

ater

con

tam

inat

ion

Som

e pe

ople

who

drin

k w

ater

con

tain

ing

trans

-1,2

-di

chlo

roet

hyle

ne in

exc

ess o

f the

MC

L ov

er m

any

year

s m

ay e

xper

ienc

e liv

er p

robl

ems.

Dic

hlor

omet

hane

ppb

54

Dis

char

ge fr

om p

harm

aceu

tical

and

ch

emic

al fa

ctor

ies;

inse

ctic

ide

Som

e pe

ople

who

drin

k w

ater

con

tain

ing

dich

loro

met

hane

in e

xces

s of t

he M

CL

over

man

y ye

ars

may

exp

erie

nce

liver

pro

blem

s and

may

hav

e an

in

crea

sed

risk

of g

ettin

g ca

ncer

.1,

2-D

ichl

orop

ropa

nepp

b5

0.5

Dis

char

ge fr

om in

dust

rial c

hem

ical

fa

ctor

ies;

prim

ary

com

pone

nt o

f so

me

fum

igan

ts

Som

e pe

ople

who

use

wat

er c

onta

inin

g 1,

2-di

chlo

ropr

opan

e in

exc

ess o

f the

MC

L ov

er m

any

year

s m

ay h

ave

an in

crea

sed

risk

of g

ettin

g ca

ncer

.1,

3-D

ichl

orop

rope

nepp

t50

020

0R

unof

f/lea

chin

g fr

om n

emat

ocid

e us

ed o

n cr

opla

nds

Som

e pe

ople

who

use

wat

er c

onta

inin

g 1,

3-di

chlo

ropr

open

e in

exc

ess o

f the

MC

L ov

er m

any

year

s m

ay h

ave

an in

crea

sed

risk

of g

ettin

g ca

ncer

.Et

hylb

enze

nepp

b30

030

0D

isch

arge

from

pet

role

um

refin

erie

s; in

dust

rial c

hem

ical

fa

ctor

ies

Som

e pe

ople

who

use

wat

er c

onta

inin

g et

hylb

enze

ne in

ex

cess

of t

he M

CL

over

man

y ye

ars m

ay e

xper

ienc

e liv

er o

r kid

ney

prob

lem

s.M

ethy

l-ter

t-but

yl e

ther

ppb

1313

Leak

ing

unde

rgro

und

stor

age

tank

s;

disc

harg

es fr

om p

etro

leum

and

ch

emic

al fa

ctor

ies

Som

e pe

ople

who

use

wat

er c

onta

inin

g m

ethy

l-ter

t-bu

tyl e

ther

in e

xces

s of t

he M

CL

over

man

y ye

ars m

ay

have

an

incr

ease

d ris

k of

get

ting

canc

er.

Mon

ochl

orob

enze

nepp

b70

200

Dis

char

ge fr

om in

dust

rial a

nd

agric

ultu

ral c

hem

ical

fact

orie

s and

dr

ycle

anin

g fa

cilit

ies

Som

e pe

ople

who

use

wat

er c

onta

inin

g m

onoc

hlor

oben

zene

in e

xces

s of t

he M

CL

over

man

y ye

ars m

ay e

xper

ienc

e liv

er o

r kid

ney

prob

lem

s.St

yren

epp

b10

0(1

00)

Dis

char

ge fr

omru

bber

and

pla

stic

fa

ctor

ies;

leac

hing

from

land

fills

Som

e pe

ople

who

drin

k w

ater

con

tain

ing

styr

ene

in

exce

ss o

f the

MC

L ov

er m

any

year

s may

exp

erie

nce

liver

, kid

ney,

or c

ircul

ator

y sy

stem

pro

blem

s.1,

1,2,

2-Te

trach

loro

etha

nepp

b1

0.1

Dis

char

ge fr

om in

dust

rial a

nd

agric

ultu

ral c

hem

ical

fact

orie

s;

solv

ent u

sed

in p

rodu

ctio

n of

TC

E,

pest

icid

es, v

arni

sh a

nd la

cque

rs

Som

e pe

ople

who

drin

k w

ater

con

tain

ing

1,1,

2,2-

tetra

chlo

roet

hane

in e

xces

s of t

he M

CL

over

man

y ye

ars

may

exp

erie

nce

liver

or n

ervo

us sy

stem

pro

blem

s.

Tetra

chlo

roet

hyle

ne (P

CE)

ppb

50.

06D

isch

arge

from

fact

orie

s, dr

y cl

eane

rs, a

nd a

uto

shop

s (m

etal

de

grea

ser)

Som

e pe

ople

who

use

wat

er c

onta

inin

g te

trach

loro

ethy

lene

in e

xces

s of t

he M

CL

over

man

y ye

ars m

ay e

xper

ienc

e liv

er p

robl

ems,

and

may

hav

ean

in

crea

sed

risk

of g

ettin

g ca

ncer

.1,

2,4-

Tric

hlor

oben

zene

ppb

55

Dis

char

ge fr

om te

xtile

-fini

shin

g fa

ctor

ies

Som

e pe

ople

who

use

wat

er c

onta

inin

g 1,

2,4-

trich

loro

benz

ene

in e

xces

s of t

he M

CL

over

man

y ye

ars

may

exp

erie

nce

adre

nal g

land

cha

nges

.

2009

SW

S C

CR

Form

s &

Inst

ruct

ions

Revi

sed

Jan

2010

CC

R In

stru

ctio

ns –

Atta

chm

ents

1

Page

2of

3

Con

tam

inan

tU

nit

Mea

sure

men

t

MC

L[M

RD

L]

PHG

(MC

LG

)[M

RD

LG

]

Typ

ical

Sou

rce

of

Con

tam

inan

tH

ealth

Eff

ects

Lan

guag

e

1,1,

1-Tr

ichl

oroe

than

epp

b20

010

00D

isch

arge

from

met

al d

egre

asin

g si

tes a

nd o

ther

fact

orie

s;

man

ufac

ture

of f

ood

wra

ppin

gs

Som

e pe

ople

who

use

wat

er c

onta

inin

g 1,

1,1-

trich

loro

etha

ne in

exc

ess o

f the

MC

L ov

er m

any

year

s m

ay e

xper

ienc

e liv

er, n

ervo

us sy

stem

, or c

ircul

ator

y sy

stem

pro

blem

s.1,

1,2-

Tric

hlor

oeth

ane

ppb

50.

3D

isch

arge

from

indu

stria

l che

mic

al

fact

orie

sSo

me

peop

le w

ho u

se w

ater

con

tain

ing

1,1,

2-tri

chlo

roet

hane

in e

xces

s of t

he M

CL

over

man

y ye

ars

may

exp

erie

nce

liver

, kid

ney,

or i

mm

une

syst

em

prob

lem

s.Tr

ichl

oroe

thyl

ene

(TC

E)pp

b5

1.7

Dis

char

ge fr

om m

etal

deg

reas

ing

site

s and

oth

er fa

ctor

ies

Som

e pe

ople

who

use

wat

er c

onta

inin

g tri

chlo

roet

hyle

ne in

exc

ess o

f the

MC

L ov

er m

any

year

s m

ay e

xper

ienc

e liv

er p

robl

ems a

nd m

ay h

ave

an

incr

ease

d ris

k of

get

ting

canc

er.

Tolu

ene

ppb

150

150

Dis

char

ge fr

om p

etro

leum

and

ch

emic

al fa

ctor

ies;

und

ergr

ound

gas

ta

nk le

aks

Som

e pe

ople

who

use

wat

er c

onta

inin

g to

luen

e in

ex

cess

of t

he M

CL

over

man

y ye

ars m

ay e

xper

ienc

e ne

rvou

s sys

tem

, kid

ney,

or l

iver

pro

blem

s.Tr

ichl

orof

luor

omet

hane

ppb

150

700

Dis

char

ge fr

om in

dust

rial f

acto

ries;

de

grea

sing

solv

ent;

prop

ella

nt a

nd

refr

iger

ant

Som

e pe

ople

who

use

wat

er c

onta

inin

g tri

chlo

roflu

orom

etha

ne in

exc

ess o

f the

MC

L ov

er m

any

year

s may

exp

erie

nce

liver

pro

blem

s.1,

1,2-

Tric

hlor

o-1,

2,2-

triflu

oroe

than

epp

m1.

24

Dis

char

ge fr

om m

etal

deg

reas

ing

site

s and

oth

erfa

ctor

ies;

dr

ycle

anin

g so

lven

t; re

frig

eran

t

Som

e pe

ople

who

use

wat

er c

onta

inin

g 1,

1,2-

trich

loro

-1,

2,2-

triflo

roet

hane

in e

xces

s of t

he M

CL

over

man

y ye

ars m

ay e

xper

ienc

e liv

er p

robl

ems.

Vin

yl c

hlor

ide

ppt

500

50Le

achi

ng fr

om P

VC

pip

ing;

di

scha

rge

from

pla

stic

s fac

torie

s;

biod

egra

datio

n by

prod

uct o

f TC

E an

d PC

E gr

ound

wat

er

cont

amin

atio

n

Som

e pe

ople

who

use

wat

er c

onta

inin

g vi

nyl c

hlor

ide

in

exce

ss o

f the

MC

L ov

er m

any

year

s may

hav

e an

in

crea

sed

risk

of g

ettin

g ca

ncer

.

Xyl

enes

ppm

1.75

01.

8D

isch

arge

from

pet

role

um a

nd

chem

ical

fact

orie

s; fu

el so

lven

tSo

me

peop

le w

ho u

se w

ater

con

tain

ing

xyle

nes i

n ex

cess

of t

he M

CL

over

man

y ye

ars m

ay e

xper

ienc

e ne

rvou

s sys

tem

dam

age.

2009

SW

S C

CR

Form

s &

Inst

ruct

ions

Revi

sed

Jan

2010

CC

R In

stru

ctio

ns –

Atta

chm

ents

1

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